A DPF cleaning warning system, method and engineering machinery

Abstract

The present invention relates to the technical field of engineering machinery, and discloses a DPF cleaning warning system, method, and engineering machinery, comprising an engine, a DOC, a DPF, a control unit, a display unit, and a differential pressure sensor; the rear end of the engine is sequentially connected to the DOC and the DPF; the differential pressure sensor is disposed on the DPF and is used to collect differential pressure data between the inlet and outlet of the DPF; the differential pressure sensor and the display unit are respectively communicatively connected to the control unit; and the engine and the control unit are communicatively connected to each other. The present invention has the following beneficial effects: based on the current operating conditions, the ash content in the DPF is calculated after DPF regeneration, and the remaining operating time of the DPF until the cleaning time is deduced.

Description

Technical Field

[0001] The present invention relates to the technical field of engineering machinery, and in particular to a DPF cleaning warning system, method and engineering machinery. Background Art

[0002] A particulate filter, or DPF for short, is a device installed in the engine exhaust system to reduce particulate matter in the exhaust by filtering.

[0003] As non-road diesel mobile machinery emissions are upgraded from National III to National IV, in order to meet emission requirements, most construction machinery uses diesel engine after-treatment systems, which include DOC (DOC is an oxidation catalytic converter) and DPF. DPF is used to intercept medium-sized particulate matter in the exhaust. As particulate matter accumulates in the DPF, when it accumulates to a certain level, it is burned and eliminated through DPF regeneration. DPF regeneration only burns the combustible particulate matter accumulated inside the DPF, and the non-combustible ash still remains in the DPF. The ash remaining in the DPF mainly comes from inorganic matter and ash in the engine oil.

[0004] In existing engineering machinery designs, as particulate matter accumulates in the DPF, when it reaches a certain level, it is eliminated through DPF regeneration and combustion, but unburnable ash remains in the DPF. Furthermore, as the DPF ages, the unburnable ash accumulates to a certain level, necessitating DPF cleaning and maintenance. When the unburnable ash in the DPF reaches its maximum capacity, failure to perform timely cleaning can lead to frequent DPF regenerations, increased fuel consumption, increased exhaust back pressure, and reduced engine efficiency. Alternatively, a DPF blockage alarm may occur, triggering the engine protection system and impacting engine performance.

[0005] The DPF cleaning and maintenance can be based on a fixed interval period, or a DPF cleaning reminder can be set. However, most of the DPF cleaning reminders currently set only remind you when the ash content in the DPF has reached the maximum value, and no early warning can be given. At this time, the user must suspend the current operation of the construction machinery and wait for professional service personnel to come for cleaning and maintenance. The cleaning operation takes a long time, affecting the progress of the project.

[0006] Chinese invention patent CN11636952A discloses a vehicle cleaning control device and method. By adding an oil quality sensor and a fuel quality sensor to the vehicle, when the inorganic matter integral information reaches the design threshold, a cleaning instruction is generated to perform cleaning. However, the remaining operating time of the DPF from the cleaning moment cannot be calculated to remind the user in advance.

[0007] Chinese invention patent CN104508263A discloses a method for detecting abnormally frequent diesel particulate filter regeneration, an engine and exhaust aftertreatment system, and a warning system and method. The method compares a soot load estimate based on pressure drop with a soot load estimate based on emissions. If the difference between the soot load estimate based on pressure drop and the soot load estimate based on emissions exceeds a predetermined value, a warning is provided. This method addresses the issue of carbon load regeneration and does not calculate the remaining time required for cleaning.

[0008] Under the existing technology, the carbon load that can be burned by the engine can generally be burned by increasing the engine load rate or post-injecting fuel to increase the exhaust temperature to burn the carbon load of the DPF, and regeneration can be performed without stopping. For example, Chinese invention patent CN202210918401 discloses a DPF carbon load prediction method, device and storage medium based on the XGBOOST algorithm. The patent predicts the carbon load of the engine at future times through the DPF carbon load prediction model based on the engine state parameters carbon load, oil pressure, cumulative mileage and cumulative fuel consumption. However, the patent predicts the combustible carbon load, but cannot predict the burned ash. Moreover, when predicting the carbon load, the patent assumes that the current carbon load is known, and does not describe in detail how the current carbon load is calculated. Summary of the Invention

[0009] In response to the shortcomings of the existing technology, the present invention provides a DPF cleaning warning system, method and engineering machinery, which can calculate the ash content in the DPF after DPF regeneration according to the current operating conditions, deduce the remaining working time of the DPF before the cleaning time, and use other display methods such as the whole machine instrument to remind the user.

[0010] To achieve the above object, the present invention provides the following technical solutions:

[0011] A DPF cleaning warning system includes an engine, a DOC, a DPF, a control unit, a display unit and a pressure differential sensor; the tail of the engine is connected to the DOC and the DPF in sequence; the pressure differential sensor is arranged on the DPF and is used to collect pressure differential data between the inlet and outlet of the DPF; the pressure differential sensor and the display unit are respectively communicated with the control unit; the engine and the control unit are communicated with each other; the pressure differential sensor is used to transmit the collected pressure differential data to the control unit; the engine transmits the current DPF regeneration status to the control unit; the control unit calculates the remaining time for DPF cleaning based on the total fuel consumption and the ash content in the DPF or the total fuel consumption and the pressure differential data, and transmits the time to the display unit, which is displayed by the display unit to remind the user to choose a convenient time for DPF cleaning.

[0012] In combination with the first aspect, further, the dust cleaning warning system of the present invention further includes an SCR, and the input end of the SCR is connected to the output end of the DPF.

[0013] In combination with the first aspect, further, the differential pressure sensor includes two pressure sensors and a differential amplifier, one pressure sensor is arranged at the input end of the DPF to measure the inlet pressure of the DPF, and the other pressure sensor is arranged at the output end of the DPF to measure the outlet pressure of the DPF. The differential amplifier is used to subtract the output signals of the two pressure sensors to obtain pressure difference data.

[0014] In combination with the first aspect, further, the DPF regeneration status includes regeneration start, regeneration end and regeneration in progress, and the control unit obtains from the data transmitted from the engine whether the current DPF is in regeneration start, regeneration end or regeneration in progress.

[0015] In combination with the first aspect, the dust cleaning warning system of the present invention further includes a vehicle-mounted networking terminal and a cloud data platform. The vehicle-mounted networking terminal is communicatively connected to the control unit and the cloud data platform respectively, and the control unit uploads the data it obtains or calculates to the cloud data platform through the vehicle-mounted networking terminal.

[0016] In combination with the first aspect, the dust cleaning warning system of the present invention further includes an oil level sensor, which is arranged on the engine oil pan and is used to measure the oil level in the engine oil pan, and then obtain the oil capacity in the engine oil pan; the oil level sensor is communicatively connected to the control unit, and transmits the collected oil capacity in the engine oil pan to the control unit. The control unit obtains the oil consumption through the oil capacity, and then obtains the total fuel consumption through the oil consumption and the engine-fuel ratio.

[0017] In a second aspect, the present invention provides a DPF cleaning early warning method, comprising the following steps:

[0018] Step 1: Preset the DPF pressure difference calculation model in the control unit, and obtain the theoretical pressure difference P at each moment through the DPF pressure difference calculation model;

[0019] Specifically, the DPF pressure difference calculation model is trained based on the engine state parameters at the time of the new engine (engine state parameters include engine speed n, engine load rate u and DPF pressure difference P), and the functional relationship between the DPF pressure difference and the engine speed and engine load rate is trained, that is, P = f(n,u), and the DPF pressure difference P0 at the initial moment of the new engine is calculated.

[0020] Furthermore, the DPF pressure difference calculation model is a MAP diagram between P and n and u, and this MAP diagram can be obtained by calibration on an engine test bench.

[0021] Step 2: Obtain the DPF theoretical pressure difference P at the end of engine regeneration based on the DPF pressure difference calculation model 后 , P 后 Compare this with the actual DPF differential pressure Pa transmitted from the DPF differential pressure sensor to the control unit to obtain the DPF differential pressure increase △P caused by internal ash, △P=Pa-P 后 ;

[0022] Specifically, the control unit calculates the DPF theoretical pressure difference P at the current moment based on the engine state parameters after the engine regeneration is completed (engine speed n1 after the engine regeneration is completed, engine load rate u1 after the engine regeneration is completed) using the DPF pressure difference calculation model. 后 =f(n1,u1), and compare it with the actual DPF differential pressure Pa read by the DPF differential pressure sensor 8 at the current moment, and calculate the DPF differential pressure increase caused by the internal ash in the DPF △P=Pa-P 后 .

[0023] Step 3: The control unit obtains the total fuel consumption F at the end of engine regeneration, and obtains the functional relationship between the DPF pressure difference increase ΔP and the total fuel consumption F by fitting a large amount of test data;

[0024] Step 4: Based on the DPF maximum allowable pressure difference ΔPmax preset in the control unit, the maximum fuel consumption Fmax consumed at ΔPmax is obtained according to the functional relationship between the DPF pressure difference increase ΔP and the total fuel consumption F;

[0025] Step 5: The control unit reads the average hourly fuel consumption S at the time of regeneration completion, and calculates the remaining operating time T of the DPF until the cleaning time based on the current total fuel consumption F and the maximum fuel consumption Fmax, where T = (Fmax-F) / S.

[0026] Step 6: The calculated remaining working time T is displayed on the display unit to remind the user to arrange dust cleaning reasonably according to the remaining time.

[0027] In combination with the second aspect, the dust cleaning warning method further includes step 7, which is: the control unit transmits the calculated remaining working time T to the cloud data platform through the on-board network terminal, and performs statistical analysis on the remaining dust cleaning time of multiple vehicles, so as to coordinate the arrangement of service personnel to perform active dust cleaning.

[0028] Furthermore, the DPF pressure difference calculation model in the control unit can also be preset on the cloud data platform, and the engine operating condition data (including total fuel consumption F1, engine speed n, engine load rate u, DPF pressure difference P, working time T, DPF regeneration status) is forwarded to the cloud data platform through the on-board network terminal.

[0029] In a third aspect, the present invention proposes a DPF cleaning warning method, which uses the above-mentioned cleaning warning system to calculate the remaining working time of the DPF until the cleaning time.

[0030] The control unit has a preset calculation model for exhaust flow, which can be calibrated through engine bench testing, as follows:

[0031] Q=g(n, u) (1)

[0032] Where Q is the exhaust flow rate, n is the engine speed, and u is the engine load rate.

[0033] In combination with the third aspect, further, the control unit obtains the ash content M in the current DPF by querying the ash MAP table built into the control unit based on the pressure difference P read by the pressure difference sensor and the exhaust volume flow Q calculated by the exhaust flow calculation model formula.

[0034] In combination with the third aspect, further, the control unit calculates the DPF cleaning remaining time T after the most recent regeneration is completed according to the following formula (2);

[0035] T=(M max -M) / (R*S) (2)

[0036] Among them, M max is the maximum ash capacity of DPF, which is a known quantity; R is the ash increase rate; S is the average hourly fuel consumption.

[0037] In combination with the third aspect, the control unit further calculates the fuel consumption ΔF between two regenerations based on the total fuel consumption F obtained at the end of each DPF regeneration, where ΔF = the total fuel consumption F2 at the end of the most recent regeneration - the total fuel consumption F1 at the end of the previous regeneration.

[0038] In combination with the third aspect, the control unit further calculates the ash increase rate R based on the fuel consumption △F during the two regenerations and the ash increase △M at the end of the two regenerations, R = △M / △F; the ash increase rate R represents the amount of ash accumulated in the DPF per unit fuel consumed.

[0039] In combination with the third aspect, the control unit can further calculate the average hourly fuel consumption C of the engine within a certain time period ΔT after the regeneration ends, and the time interval ΔT can be 3-5 hours; the average hourly fuel consumption C can also be the average hourly fuel consumption between two regenerations.

[0040] Furthermore, the average hourly fuel consumption C can be the average hourly fuel consumption C1 or the average hourly engine oil consumption C2; when the fuel consumption is used to calculate the remaining DPF cleaning time T, the average hourly fuel consumption C1 = fuel consumption within △T / time interval △T; when the engine oil consumption is used to calculate the remaining DPF cleaning time T, the average hourly engine oil consumption C2 = engine oil consumption within △T / time interval △T.

[0041] In combination with the third aspect, the control unit further outputs the calculated result T to a display unit to display the remaining time for DPF cleaning, reminding the user to properly arrange cleaning and maintenance. The display unit can be a whole instrument or other display device capable of displaying messages.

[0042] In combination with the third aspect, the dust cleaning early warning method of the present invention further comprises the following steps:

[0043] Step S1: When the control unit receives a DPF regeneration end state signal, it records the total fuel consumption F1, the operating time T1, and the DPF pressure difference P1 at this time, and obtains the exhaust flow rate Q1 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P1 and the calculated exhaust flow rate Q1, and obtains the ash content in the DPF at this time as M1;

[0044] Step S2: When the control unit receives the DPF regeneration end state signal again, it records the total fuel consumption F2, the operating time T2, and the DPF pressure difference P2 at this time; and obtains the exhaust flow rate Q2 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P2 and the calculated exhaust flow rate Q2, and obtains the ash content in the DPF at this time as M2;

[0045] Step S3: The control unit calculates the following parameters between two regeneration intervals based on the results recorded in steps S1 and S2:

[0046] Fuel consumption △F:

[0047] △F=F2-F1

[0048] Ash content increase △M:

[0049] △M=M2-M1

[0050] The control unit calculates the ash content increase rate R according to the fuel consumption ΔF during the two regenerations and the ash content increase ΔM at the end of the two regenerations, where R=ΔM / ΔF;

[0051] Ash increase rate R:

[0052] R=△M / △F=(M2-M1) / (F2-F1)

[0053] Step S4: Calculate the average hourly fuel consumption C1, where the average hourly fuel consumption C1 = fuel consumption within ΔT / time interval ΔT;

[0054] Step S5: The control unit calculates the remaining DPF cleaning time T after the most recent regeneration according to the calculation results of steps S3 and S4 and the following formula:

[0055] T=(Mmax-M) / (R*C1)=(Mmax-M2) / (R*C1)

[0056] Among them, M max is the maximum ash holding capacity of DPF, which is a known quantity;

[0057] Step S6: The control unit displays the remaining DPF cleaning time T calculated in step S5 through the display unit to remind the user of the remaining DPF cleaning time under the current operating conditions.

[0058] In combination with the third aspect, the dust cleaning warning method further includes step S7, and the step S7 is: the control unit transmits the calculated remaining working time T to the cloud data platform through the on-board network terminal, and performs statistical analysis on the remaining dust cleaning time of multiple vehicles, so as to coordinate and arrange service personnel to perform active dust cleaning.

[0059] In a fourth aspect, the present invention proposes a DPF cleaning warning method, which uses the above-mentioned cleaning warning system to calculate the remaining operating time of the DPF until the cleaning time, including the following steps:

[0060] Step I: When the control unit receives the DPF regeneration end status signal, it records the oil capacity J1, the operating time T1, and the DPF pressure difference P1 at this time, and obtains the exhaust flow rate Q1 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P1 and the calculated exhaust flow rate Q1, and obtains the ash content in the DPF at this time as M1;

[0061] Step II: When the control unit receives the DPF regeneration end status signal again, it records the oil capacity J2, the operating time T2, and the DPF pressure difference P2 at this time; and obtains the exhaust flow rate Q2 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P2 and the calculated exhaust flow rate Q2, and obtains the ash content in the DPF at this time as M2;

[0062] Step III: The control unit calculates the following parameters between two regeneration intervals based on the results recorded in Steps I and II:

[0063] Oil consumption △J:

[0064] △J=J2-J1

[0065] Ash content increase △M:

[0066] △M=M2-M1

[0067] Ash increase rate R:

[0068] R=△M / △J=(M2-M1) / (J2-J1)

[0069] Step IV: Calculate the average hourly oil consumption C2, where C2 = oil consumption within ΔT / time interval ΔT.

[0070] Step V: The control unit calculates the remaining DPF cleaning time T after the most recent regeneration based on the calculation results of steps III and IV and the following formula:

[0071] T=(Mmax-M) / (R*C2)=(Mmax-M2) / (R*C2)

[0072] Among them, M max is the maximum ash holding capacity of DPF, which is a known quantity;

[0073] Step VI: The control unit displays the remaining DPF cleaning time T calculated in step V through the display unit to remind the user of the remaining DPF cleaning time under the current operating conditions.

[0074] In a fifth aspect, the present invention proposes an engineering machine comprising the above-mentioned dust cleaning warning system.

[0075] In a sixth aspect, the present invention proposes an engineering machine, which uses the above-mentioned dust cleaning warning method to calculate the ash content in the DPF of the engineering machine after DPF regeneration, and calculates the remaining working time of the DPF from the dust cleaning moment.

[0076] Compared with the prior art, the present invention provides a DPF cleaning warning system, method and engineering machinery, which have the following beneficial effects:

[0077] (1) The dust cleaning warning system of the present invention can calculate the ash content in the DPF after DPF regeneration according to the current operating conditions, deduce the remaining working time of the DPF until the dust cleaning time, and use other display methods such as the whole machine instrument to remind the user.

[0078] (2) The dust cleaning warning system of the present invention can use the historical record data of the engine's operating conditions and the current resistance characteristics of the DPF to predict the ash accumulation trend of the DPF without adding additional sensors or other detection instruments, and realize the prediction of the remaining time for DPF dust cleaning, so as to remind the user to choose the appropriate time for dust cleaning maintenance.

[0079] (3) With the dust cleaning warning system of the present invention, users can independently select the idle time of the construction machinery to perform dust cleaning and maintenance according to the remaining time of DPF dust cleaning, thereby avoiding stopping the excavator for dust cleaning and maintenance during operation and improving the attendance rate of the excavator.

[0080] (4) The dust cleaning warning method of the present invention can calculate the ash content in the DPF after DPF regeneration according to the current operating conditions, deduce the remaining working time of the DPF before the dust cleaning moment, and use other display methods such as the whole machine instrument to remind the user.

[0081] (5) The engineering machinery of the present invention can calculate the ash content in the DPF after DPF regeneration according to the current operating conditions, deduce the remaining working time of the DPF until the ash is cleaned, and use other display methods such as the whole machine instrument to remind the user. BRIEF DESCRIPTION OF THE DRAWINGS

[0082] Figure 1 Schematic diagram of the composition of the dust cleaning early warning system in Example 1 of the present invention;

[0083] Figure 2 This is a flow chart of the dust cleaning early warning method according to Example 1 of the present invention;

[0084] Figure 3 Schematic diagram of a method for calculating the remaining operating time of the DPF until the dust cleaning moment in the dust cleaning warning method of Example 1 of the present invention;

[0085] Figure 4 Schematic diagram of the composition of the dust cleaning warning system in Example 2 of the present invention.

[0086] The meanings of the reference numerals in the figures are:

[0087] 1-Engine; 2-DOC; 3-DPF; 4-SCR; 5-Oil level sensor; 6-Control unit; 7-Display unit; 8-Differential pressure sensor; 9-In-vehicle networking terminal; 10-Cloud data platform. DETAILED DESCRIPTION

[0088] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0089] Unless otherwise specifically stated, the relative arrangement, numerical expressions and numerical values of the parts and steps set forth in these embodiments do not limit the scope of the present invention. Meanwhile, it should be understood that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to actual proportional relationships. Technology, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be considered as a part of the specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may also include different values. It should be noted that similar numbers and letters represent similar items in the following drawings, and therefore, once an item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.

[0090] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the protection content of the present invention.

[0091] Example 1

[0092] like Figure 1As shown, the cleaning warning system of the present invention includes an engine 1, DOC2, a DPF3 control unit 6, a display unit 7 and a pressure difference sensor 8; the tail of the engine 1 is connected to the DOC2 and DPF3 in sequence; the pressure difference sensor 8 is arranged on the DPF3, and is used to collect the pressure difference data between the inlet and outlet of the DPF3; the pressure difference sensor 8 and the display unit 7 are respectively communicated with the control unit 6; the engine and the control unit are communicated with each other; the pressure difference sensor is used to transmit the collected pressure difference data to the control unit; the engine 1 transmits the current DPF3 regeneration status to the control unit 6; the control unit 6 obtains the remaining time for DPF3 cleaning based on the total fuel consumption and the ash content in the DPF3 or the total fuel consumption and the pressure difference data, and transmits the time to the display unit 7, which is displayed by the display unit 7 to remind the user to choose a convenient time for DPF cleaning.

[0093] In a specific implementation of this embodiment, the pressure difference sensor 8 and the display unit 7 may be electrically connected to the control unit 6 or may communicate via a bus.

[0094] To meet the non-road National IV emission requirements, engines 1 equipped with DPF3 are all electronically controlled engines, and the regeneration status, total fuel consumption and operating time of DPF3 can be broadcast externally through the engine controller.

[0095] The DPF3 is used to filter particulate matter and ash from exhaust gas. Particulate matter in the DPF3 is burned through DPF3 regeneration, while unburned ash remains in the DPF3. When the remaining ash reaches the DPF3's maximum allowable ash capacity, the DPF3 requires cleaning and maintenance to remove the ash and restore DPF3 performance. The DPF3's maximum ash capacity (Mmax) is the maximum ash capacity within the allowable DPF3 pressure differential range when the engine is operating at rated operating conditions and the exhaust gas flows through post-treatment. This can be determined through calibration on the Engine 1 test bench.

[0096] Differential pressure sensor 8 measures the differential pressure generated by exhaust gas flowing through DPF 3. After DPF 3 regeneration, particulate matter in DPF 3 is burned, leaving only incombustible ash. The relationship between differential pressure, ash content, and exhaust volume flow can be determined through bench calibration.

[0097] The control unit 6 calculates the remaining time for cleaning the DPF 3 based on the total fuel consumption and the ash content in the DPF 3 , and displays the time on the display unit 6 to remind the user to select a convenient time for cleaning the DPF 3 .

[0098] In a specific implementation of this embodiment, the control unit 6 may receive the regeneration status of the DPF 3 from the engine 1 and determine whether the DPF 3 is in the regeneration start, end, or intermediate state.

[0099] In a specific implementation of this embodiment, the control unit 6 reads the current engine speed n and engine load rate u, and calculates the exhaust volume flow rate according to the exhaust flow calculation model preset in the control unit:

[0100] Q=g(n, u) (1)

[0101] Among them, Q is the exhaust flow rate, n is the engine speed, u is the engine load rate, and Q=g(n,u) is the MAP diagram between Q and n and u. To facilitate expression in functional form, this MAP diagram can be obtained through bench testing or historical operating conditions of the actual vehicle.

[0102] In a specific implementation of this embodiment, the control unit 6 can read the pressure difference P (P1, P2, ..., P i ), and the exhaust flow calculation model MAP diagram above to obtain the exhaust volume flow Q (Q1, Q2, ..., Q i ) and obtain the current ash content M in the DPF 3 by querying the ash content MAP table built into the control unit 6. The relationship between the pressure difference, ash content, and exhaust volume flow rate can be obtained through bench calibration. The MAP table is as follows:

[0103] MAP table

[0104]

[0105] Among them, i in the MAP table represents the number of data groups calibrated in the MAP table.

[0106] The control unit 6 can record the total fuel consumption F at the end of each DPF3 regeneration (it should be noted that the dust cleaning warning system in this embodiment is suitable for electronically controlled diesel engines. Because it is an electronically controlled diesel engine, the control unit 6 can directly obtain and record the data of the total fuel consumption F.) and calculate the fuel consumption △F between two regenerations, △F = the total fuel consumption F2 at the end of the most recent regeneration - the total fuel consumption F1 at the end of the previous regeneration.

[0107] In a specific implementation of this embodiment, the control unit 6 calculates the ash increase rate R based on the fuel consumption △F during the two regenerations and the ash increase △M at the end of the two regenerations (△M=M2-M1, where M2 represents the ash content in the DPF at the end of the most recent regeneration, and M1 represents the ash content in the DPF at the end of the previous regeneration, and M1 and M2 are obtained by querying the MAP table), R=△M / △F; the ash increase rate R represents the ash content accumulated in the DPF per unit fuel consumed.

[0108] In a specific implementation of this embodiment, the control unit 6 can calculate the average hourly fuel consumption C of the engine 1 within a certain time period △T after the regeneration is completed. The time interval △T can be 3-5 hours; the average hourly fuel consumption C can also be the average hourly fuel consumption between two regenerations. The smaller the value range of the time interval △T, the more it can represent the current diesel consumption rate / oil consumption rate of the whole machine, and the more accurate the final calculated remaining cleaning time. Under existing technical conditions, the regeneration cycle of the DPF (i.e., T2-T1) is generally more than 8 hours, and can even reach more than 100 hours. When the regeneration cycle of the DPF is longer (i.e., T2-T1), such as 100 hours, if the average hourly fuel consumption between two regenerations is used at this time, the calculated remaining cleaning time will have a large error, so the parameter of the average hourly fuel consumption C is introduced into the calculation of the remaining cleaning time of the present invention.

[0109] In a specific implementation of this embodiment, the control unit 6 calculates the remaining time T for cleaning the DPF 3 after the most recent regeneration is completed according to the following formula (2).

[0110] T=(M max -M2) / (R*C) (2)

[0111] In a specific implementation of this embodiment, the control unit 6 outputs the calculated result T to the display unit 7 to display the remaining time for cleaning the DPF 3, reminding the user to properly arrange cleaning and maintenance. The display unit can be a whole instrument or other display device capable of displaying messages.

[0112] In one embodiment of this invention, the dust cleaning warning system further includes a selective catalytic reduction device (SCR4), the input of which is connected to the output of DPF 3. Exhaust gas from engine 1 passes through DOC 2, DPF 3, and SCR4 in sequence before being discharged into the atmosphere. Due to differences in emission control technology, SCR4 is not required.

[0113] In a specific implementation of this embodiment, the differential pressure sensor 8 includes two pressure sensors and a differential amplifier. One pressure sensor is arranged at the input end of DPF3 to measure the inlet pressure of DPF3, and the other pressure sensor is arranged at the output end of DPF3 to measure the outlet pressure of DPF3. The differential amplifier is used to subtract the output signals of the two pressure sensors to obtain pressure difference data.

[0114] like Figure 2 and Figure 3 As shown, the dust cleaning early warning method of the present invention includes the following steps:

[0115] Step S1: When the control unit 6 receives the regeneration end state signal of the DPF 3, it records the total fuel consumption F1, the operation time T1 and the pressure difference of the DPF P1 at this time;

[0116] According to the exhaust flow calculation model, the exhaust volume flow at this time is Q1; the control unit 6 queries the ash content MAP table based on the recorded DPF3 pressure difference P1 and the calculated exhaust volume flow Q1, and obtains that the ash content in the DPF3 at this time is M1;

[0117] Step S2: When the control unit 6 receives the DPF 3 regeneration end status signal again, it records the total fuel consumption F2, the operating time T2, and the DPF pressure difference P2 at this time; and obtains the exhaust volume flow rate Q2 at this time based on the exhaust flow calculation model; and the control unit queries the ash content MAP table based on the recorded DPF pressure difference P2 and the calculated exhaust flow rate Q2, and obtains the ash content M2 in the DPF at this time;

[0118] Step S3: The control unit 6 calculates the following parameters during the interval between two regenerations based on the results recorded in steps S1 and S2:

[0119] Fuel consumption △F:

[0120] △F=F2-F1 (3)

[0121] Ash content increase △M:

[0122] △M=M2-M1 (4)

[0123] Average hourly fuel consumption S:

[0124] S=(F2-F1) / (T2-T1) (5)

[0125] Ash increase rate R:

[0126] R=△M / △F= (M2-M1) / (F2-F1) (6)

[0127] Step S4: Calculate the average hourly fuel consumption C1, where the average hourly fuel consumption C1 = fuel consumption within ΔT / time interval ΔT;

[0128] Step S5: The control unit 6 calculates the remaining time of DPF cleaning according to the calculation results of steps S3 and S4 and formula (2).

[0129] Step S6: the control unit 6 displays the result calculated in step S5 via the display unit 7 to remind the user of the remaining time for cleaning the DPF 3 under the current operating conditions.

[0130] The engineering machinery of the present invention includes the above-mentioned dust cleaning warning system, and uses the above-mentioned dust cleaning warning method to calculate the ash content in the DPF3 of the engineering machinery after the DPF3 is regenerated, and calculates the remaining working time of the DPF3 to the dust cleaning moment.

[0131] Example 2

[0132] The difference between Example 2 and Example 1 is that, compared with Example 1, the dust cleaning warning system in Example 2 further includes an on-board network terminal 9 and a cloud data platform 10, and the on-board network terminal 9 is communicatively connected to the control unit 8 and the cloud data platform 10, respectively. The control unit 8 can upload the remaining DPF cleaning time of each vehicle to the cloud data platform 10 via the on-board network terminal 9. After the cloud data platform 10 collects the remaining DPF cleaning time of each vehicle, it can perform a statistical analysis of the time distribution based on the remaining DPF cleaning time, reasonably arrange service personnel to perform active cleaning, and adjust service resources, such as service personnel and cleaning equipment, because the DPF cleaning operation requires professional cleaning equipment and has a certain degree of operating difficulty, and ordinary end users cannot complete this operation.

[0133] The dust cleaning warning method in Example 2 has an additional step S7 parallel to step S6 compared to the dust cleaning warning method in Example 1. Step S7 is: transmitting the remaining working time T of DPF3 to the cleaning time to the cloud data platform 10 through the on-board network terminal to perform statistical analysis of the remaining cleaning time of multiple vehicles.

[0134] Example 3

[0135] The difference between Example 3 and Example 1 and Example 2 is that the dust cleaning warning method is different, and specifically includes the following steps:

[0136] Step 1: A DPF pressure difference calculation model is preset in the control unit 6. The DPF pressure difference calculation model is trained according to the engine state parameters (engine speed n, engine load rate u, DPF pressure difference P) at the time of the new engine. The functional relationship between the DPF pressure difference and the engine speed and engine load rate is trained, that is, P = f(n,u), and the DPF pressure difference P0 at the initial time of the new engine is calculated; the calculation model is a MAP diagram between P and n, u, and this MAP diagram can also be calibrated by an engine test bench.

[0137] Step 2: The control unit 6 calculates the DPF pressure difference P1=f(n1,u1) at the current moment using the DPF pressure difference calculation model based on the engine state parameters (engine speed n1, engine load rate u1) after the engine regeneration is completed, and compares it with the DPF pressure difference Pa read by the DPF pressure difference sensor 8 at the current moment to calculate the DPF pressure difference increase △P=Pa-P1 caused by the internal ash of the DPF.

[0138] Step 3: The control unit 6 reads the total fuel consumption F after the regeneration is completed, and obtains a functional relationship between the DPF pressure difference increase ΔP and the total fuel consumption F through fitting.

[0139] Step 4: The control unit 6 internally presets the maximum allowable DPF pressure difference ΔPmax. Based on the functional relationship between the DPF pressure difference increase ΔP and the total fuel consumption F, the maximum fuel consumption Fmax consumed at ΔPmax can be calculated.

[0140] Step 5: The control unit 6 reads the average hourly fuel consumption C1 at the current moment of regeneration completion, and calculates the remaining operating time T = (Fmax-F) / C1 of the DPF until the dust cleaning time based on the current total fuel consumption F and the maximum fuel consumption Fmax.

[0141] Step 6: The calculated remaining working time T is displayed on the display unit to remind the user to arrange dust cleaning reasonably according to the remaining time.

[0142] Step 7: The remaining working time T can also be transmitted to the cloud data platform 10 through the vehicle-mounted network terminal to perform statistical analysis on the remaining cleaning time of multiple vehicles so as to coordinate and arrange service personnel to perform active cleaning.

[0143] In a specific implementation of this embodiment, the DPF pressure difference calculation model in the control unit 6 can also be preset on the cloud data platform 10, and the operating condition data of the engine 1 (including the total fuel consumption F1, engine speed n, engine load rate u, DPF pressure difference P, working time T, DPF regeneration status) is forwarded to the cloud data platform 10 through the on-board network terminal 9. In this way, the calculation logic of steps 1 to 6 in the dust cleaning warning method proposed in the present invention is placed in the control unit or data processor of the cloud data platform 10, so that the dust cleaning warning system of the present invention does not include the control unit 6.

[0144] Example 4

[0145] The difference between Example 4 and Example 1, Example 2 and Example 3 is that the dust cleaning warning system of the present invention also includes an oil level sensor 5. The oil consumption can be obtained by setting the oil level sensor 5, and then the total fuel consumption can be obtained. It is suitable for the case where the engineering machinery is a non-electronically controlled diesel engine.

[0146] like Figure 1 and Figure 4 As shown, the oil level sensor 5 is arranged on the oil pan of the engine 1, and is used to measure the oil level in the oil pan of the engine 1, and then obtain the oil capacity in the oil pan of the engine 1; the oil level sensor 5 is communicatively connected with the control unit 6, and the oil level sensor transmits the collected oil capacity in the engine oil pan to the control unit.

[0147] Because the measurement result of oil level sensor 5 corresponds to the oil volume in the oil pan of engine 1, the oil volume in the oil pan of engine 1 and the oil consumption can be obtained through oil level sensor 5. Therefore, control unit 6 can calculate the oil consumption between two regeneration intervals and the oil consumption in a specific cycle based on the reading of oil level sensor 5, and then calculate the total fuel consumption based on the oil consumption and the engine-to-fuel ratio.

[0148] In a specific implementation of this embodiment, the oil level sensor 5 and the control unit 6 may be electrically connected or may communicate via a bus.

[0149] In a specific implementation of this embodiment, the oil level sensor 5 measures the oil level height, which is proportional to the oil capacity in the engine oil pan. Therefore, the oil level can be converted into the oil capacity according to a certain formula.

[0150] Example 5

[0151] The difference between Example 5 and Example 4 is that after the oil consumption is obtained by setting the oil level sensor 5, it is not necessary to convert the oil consumption by the engine-fuel ratio to obtain the total fuel consumption. Instead, the oil consumption is directly used to calculate the DPF cleaning remaining time T. The specific method is as follows:

[0152] Step I: When the control unit receives the DPF regeneration end status signal, it records the oil capacity J1, the operating time T1, and the DPF pressure difference P1 at this time, and obtains the exhaust flow rate Q1 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P1 and the calculated exhaust flow rate Q1, and obtains the ash content in the DPF at this time as M1;

[0153] Step II: When the control unit receives the DPF regeneration end status signal again, it records the oil capacity J2, the operating time T2, and the DPF pressure difference P2 at this time; and obtains the exhaust flow rate Q2 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P2 and the calculated exhaust flow rate Q2, and obtains the ash content in the DPF at this time as M2;

[0154] Step III: The control unit calculates the following parameters between two regeneration intervals based on the results recorded in Steps I and II:

[0155] Oil consumption △J:

[0156] △J=J2-J1

[0157] Ash content increase △M:

[0158] △M=M2-M1

[0159] Ash increase rate R:

[0160] R=△M / △J=(M2-M1) / (J2-J1)

[0161] Step IV: Calculate the average hourly oil consumption C2; average hourly oil consumption C2 = oil consumption within △T / time interval △T;

[0162] Step V: The control unit calculates the remaining DPF cleaning time T after the most recent regeneration based on the calculation results of steps III and IV and the following formula:

[0163] T=(Mmax-M) / (R*C2)=(Mmax-M2) / (R*C2)

[0164] Among them, M max is the maximum ash holding capacity of DPF, which is a known quantity;

[0165] Step VI: The control unit displays the remaining DPF cleaning time T calculated in step V through the display unit to remind the user of the remaining DPF cleaning time under the current operating conditions.

[0166] It should be noted that, in this application, relational terms such as first and second, etc. are merely used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply the existence of any such actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article, or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article, or device. In the absence of further restrictions, an element defined by the statement "comprising a ..." does not exclude the presence of other identical elements in the process, method, article, or device comprising the element.

[0167] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A DPF cleaning early warning method, characterized by: The method for calculating the remaining operating time of the DPF until the dust cleaning time includes the following steps: Step S1: When the control unit receives a DPF regeneration end state signal, it records the total fuel consumption F1, the operating time T1, and the DPF pressure difference P1 at this time, and obtains the exhaust flow rate Q1 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P1 and the calculated exhaust flow rate Q1, and obtains the ash content in the DPF at this time as M1; Step S2: When the control unit receives the DPF regeneration end state signal again, it records the total fuel consumption F2, the operating time T2, and the DPF pressure difference P2 at this time; and obtains the exhaust flow rate Q2 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P2 and the calculated exhaust flow rate Q2, and obtains the ash content in the DPF at this time as M2; Step S3: The control unit calculates the following parameters between two regeneration intervals based on the results recorded in steps S1 and S2: Fuel consumption △F: △F=F2-F1 Ash content increase △M: △M=M2-M1 Ash increase rate R: R=△M / △F= (M2-M1) / (F2-F1) Step S4: Calculate the average hourly fuel consumption C1; Average hourly fuel consumption C1 = fuel consumption within △T / time interval △T; Step S5: The control unit calculates the remaining DPF cleaning time T after the most recent regeneration according to the calculation results of steps S3 and S4 and the following formula: T=(Mmax-M) / (R C1)=(Mmax-M2) / (R C1) Among them, M max is the maximum ash holding capacity of DPF, which is a known quantity; Step S6: The control unit displays the remaining DPF cleaning time T calculated in step S5 through the display unit to remind the user of the remaining DPF cleaning time under the current operating conditions.

2. A DPF cleaning early warning method according to claim 1, characterized in that: The control unit is pre-set with an exhaust flow calculation model, which is obtained by calibration through engine bench testing. The exhaust flow calculation model is as follows: Q=g(n,u) Where Q is the exhaust flow, n is the engine speed, and u is the engine load rate; Q=g(n,u) is the MAP diagram between Q and n and u.

3. A DPF cleaning warning system, characterized by: The DPF cleaning warning method according to claim 1 or 2 is used to calculate the remaining working time of the DPF until the cleaning time, and includes an engine, a DOC, a DPF, a control unit, a display unit and a pressure differential sensor; the tail of the engine is connected to the DOC and the DPF in sequence; the pressure differential sensor is arranged on the DPF, and is used to collect the pressure differential data of the inlet and outlet of the DPF; the pressure differential sensor and the display unit are respectively communicated with the control unit; the engine and the control unit are communicated with each other; the pressure differential sensor is used to transmit the collected pressure differential data to the control unit; the engine transmits the current DPF regeneration status to the control unit; the control unit calculates the remaining time of DPF cleaning based on the total fuel consumption and the ash content in the DPF, and transmits the time to the display unit, which is displayed by the display unit to remind the user to choose a convenient time for DPF cleaning.

4. A DPF cleaning warning system according to claim 3, characterized in that: The system further includes an SCR, wherein an input terminal of the SCR is connected to an output terminal of the DPF.

5. A DPF cleaning warning system according to claim 3, characterized in that: The differential pressure sensor includes two pressure sensors and a differential amplifier. One pressure sensor is arranged at the input end of the DPF to measure the inlet pressure of the DPF, and the other pressure sensor is arranged at the output end of the DPF to measure the outlet pressure of the DPF. The differential amplifier is used to subtract the output signals of the two pressure sensors to obtain pressure difference data.

6. A DPF cleaning warning system according to claim 3, characterized in that: The dust cleaning warning system also includes an on-board networking terminal and a cloud data platform. The on-board networking terminal is communicated with the control unit and the cloud data platform respectively. The control unit uploads the data it obtains or calculates to the cloud data platform through the on-board networking terminal.

7. The DPF cleaning warning system according to claim 3, characterized in that: It also includes an oil level sensor, which is arranged on the engine oil pan and is used to measure the oil level in the engine oil pan and thus obtain the oil capacity in the engine oil pan; the oil level sensor is communicatively connected to the control unit and transmits the collected oil capacity in the engine oil pan to the control unit.

8. A DPF cleaning early warning method, characterized by: The method of calculating the remaining operating time of the DPF until the dust cleaning time by using the dust cleaning warning system according to claim 7 comprises the following steps: Step I: When the control unit receives the DPF regeneration end status signal, it records the oil capacity J1, the operating time T1, and the DPF pressure difference P1 at this time, and obtains the exhaust flow rate Q1 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P1 and the calculated exhaust flow rate Q1, and obtains the ash content in the DPF at this time as M1; Step II: When the control unit receives the DPF regeneration end status signal again, it records the oil capacity J2, the operating time T2, and the DPF pressure difference P2 at this time; and obtains the exhaust flow rate Q2 at this time based on the exhaust flow calculation model. The control unit then queries the ash content MAP table based on the recorded DPF pressure difference P2 and the calculated exhaust flow rate Q2, and obtains the ash content in the DPF at this time as M2; Step III: The control unit calculates the following parameters between two regeneration intervals based on the results recorded in Steps I and II: Oil consumption △J: △J=J2-J1 Ash content increase △M: △M=M2-M1 Ash increase rate R: R=△M / △J= (M2-M1) / (J2-J1) Step IV: Calculate the average hourly oil consumption C2; Average hourly oil consumption C2 = oil consumption within △T / time interval △T; Step V: The control unit calculates the remaining DPF cleaning time T after the most recent regeneration based on the calculation results of steps III and IV and the following formula: T=(Mmax-M) / (R C2)=(Mmax-M2) / (R C2) Among them, M max is the maximum ash holding capacity of DPF, which is a known quantity; Step VI: The control unit displays the remaining DPF cleaning time T calculated in step V through the display unit to remind the user of the remaining DPF cleaning time under the current operating conditions.

9. An engineering machine, characterized in that: Including the dust cleaning warning system according to any one of claims 3 to 7.

10. An engineering machine, characterized in that: The dust cleaning early warning method according to claim 8 is used to calculate the ash content in the DPF of the engineering machinery after DPF regeneration, and to deduce the remaining working time of the DPF until the dust cleaning moment.

11. An engineering machine, characterized in that: The dust cleaning warning method according to any one of claims 1 and 2 is used to calculate the ash content in the DPF of the engineering machinery after DPF regeneration, and to deduce the remaining working time of the DPF until the dust cleaning moment.

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