Aftertreatment system heater control

Abstract

An exhaust aftertreatment system and a method thereof are provided. The system includes a heater configured to provide heat to the catalyst. The system also includes a heater control unit (HCU) configured to supply power to the heater; and a power supply control unit (PSCU) configured to supply power to the HCU at a variable voltage. The HCU is configured to determine a setpoint parameter that varies in response to a change in a commanded power output of the HCU for driving the heater. The PSCU is configured to receive a setpoint parameter and adjust a variable voltage supplied to the HCU in response to the setpoint parameter. The adjustment of setpoint parameters may be effective to optimize the efficiency of the HCU during operation of supplying the commanded power output to the heater.

Description

Background Art

[0001] This application relates to post - treatment system heater control and related devices, processes, systems, and technologies. An exhaust after - treatment system can utilize a heater to heat a catalyst or other post - treatment system components to provide a necessary or desired operating temperature. Many suggestions have been made for controlling the post - treatment system heater catalyst of an internal combustion system. Existing post - treatment catalyst heating methods have many disadvantages, drawbacks, problems, and deficiencies. There remains a significant need for the unique devices, processes, and systems disclosed herein.

[0002] Disclosure of Exemplary Embodiments

[0003] For the purpose of clearly, concisely, and accurately describing the exemplary embodiments of the present disclosure, the manner and process of making and using the present disclosure, and for enabling the practice, manufacture, and use of the present disclosure, certain exemplary embodiments will now be referred to, including those shown in the figures, and the present disclosure will be described using specific language. However, it should be understood that no limitation to the scope of the invention is thereby created, and the invention set forth in the appended claims of the present disclosure includes and protects such changes, modifications, and further applications of the exemplary embodiments as would occur to those skilled in the art upon benefiting from the present disclosure. Summary of the Invention

[0004] Some embodiments include unique post - treatment system heater control devices. Some embodiments include unique post - treatment system heater control systems. Some embodiments include unique post - treatment system heater control processes. Additional embodiments, forms, purposes, features, advantages, aspects, and benefits will become apparent from the following description and the drawings. Brief Description of the Drawings

[0005] Figure 1 is a schematic diagram showing certain aspects of an exemplary prime - mover system.

[0006] Figure 2 is a schematic diagram showing certain aspects of an exemplary electronic control system implementation.

[0007] Figure 3 is a flowchart showing certain aspects of an exemplary control process. Detailed Description

[0008] Reference Figure 1, shows an exemplary prime mover system 100 (also referred to herein as system 100), which includes a prime mover in the form of an internal combustion engine (ICE) 102. System 100 can be provided in a variety of forms, including, for example, a vehicle or a vehicle powertrain (e.g., a road vehicle or a vehicle powertrain or an off-road vehicle or a vehicle powertrain), a work machine or a work machine powertrain, a generator set or a generator set powertrain, or a hydraulic fracturing rig or a hydraulic fracturing rig powertrain, to name just a few non-limiting examples. It should be understood that system 100 can include many other components, as would occur to those skilled in the art who benefit from and have insight into the present disclosure. Additionally, while in the illustrated embodiment engine 102 is provided as the prime mover of system 100, other embodiments can include other types of prime movers, such as a battery electric drive system, a hybrid ICE battery electric system, a fuel cell electric drive system, or a prime mover system including a combination of the foregoing and / or other types of prime mover systems, as would occur to those skilled in the art who benefit from and have insight into the present disclosure.

[0009] System 100 includes an intake system 108 and an exhaust system 110. Engine 102 is in fluid communication with intake system 108, through which boosted air enters the intake manifold 104, and the engine is also in fluid communication with exhaust system 110, through which the exhaust gas generated by combustion is discharged via the exhaust manifold 106. Engine 102 includes a plurality of cylinders (e.g., cylinders 1 to 6) that form combustion chambers, in which a boosted flow mixture of fuel and air is combusted. For example, the energy released by combustion powers engine 102 via pistons in the cylinders that are connected to a crankshaft. Intake valves control the entry of boosted air into the cylinders, and exhaust valves control the flow of exhaust out through exhaust manifold 106 and ultimately to the atmosphere. It should be understood that exhaust manifold 106 can be a single manifold or multiple exhaust manifolds.

[0010] Turbocharger 112 includes a compressor 114 that is configured to receive filtered intake air via an intake throttle (IAT) 116 of intake system 108 and is operable to compress ambient air before the ambient air enters intake manifold 104 of engine 102 at an increased pressure. Air from compressor 114 is pumped through intake system 108, reaches intake manifold 104, and enters the cylinders of engine 102, generally generating torque on the crankshaft. IAT 116 is in fluid flow coupling with a charge air cooler (CAC) 120 that is operable to cool the boosted flow provided to intake manifold 104. Intake system 108 also includes a CAC bypass valve 122 that can be opened to direct some or all of the boosted flow around CAC 120. Adjusting the bypass position of CAC bypass valve 122 incrementally raises the temperature of the gas returning to intake manifold 104.

[0011] It is contemplated that in system 100, the turbocharger 112 can be a variable geometry turbocharger (VGT) or a fixed geometry turbocharger. The variable geometry turbine allows for significant flexibility in the pressure ratio across the turbine. For example, in a diesel engine, this flexibility can be used to improve low-speed torque characteristics, reduce turbocharger lag, and drive exhaust gas recirculation flow. In an exemplary embodiment, the VGT 124 can be adjusted to increase the engine load and is thus configured to increase the exhaust gas temperature. System 100 also includes a turbo bypass valve 126 to bypass the turbocharger 112. Since cooler ambient air is introduced at the turbocharger 112, opening the turbo bypass valve 126 allows bypassing the turbocharger 112 and maintaining a higher intake air temperature at the intake manifold 104.

[0012] The exhaust system 110 includes an exhaust gas temperature sensor 128 to sense the temperature of the gases leaving the exhaust manifold 106. The exhaust system 110 includes an exhaust gas recirculation (EGR) valve 129 that recirculates a portion of the exhaust gas from the exhaust manifold 106 back to the intake manifold 104. The exhaust system 110 includes an EGR cooler (EGR-C) 118 that cools the gases leaving the exhaust manifold 106 before the gases return to the intake manifold 104. The exhaust system 110 may also include an EGR-C bypass valve 117 that can be opened to direct some or all of the recirculated exhaust gas from the exhaust manifold 106 to bypass the EGR-C 118. By increasing the amount of gas bypassing the EGR-C 118, the temperature of the gases returning to the intake manifold 104 increases. It should be understood that the intake system 108 and / or the exhaust system 110 may also include various components not shown, such as additional coolers, valves, bypasses, intake throttle valves, exhaust throttle valves, and / or compressor bypass valves.

[0013] System 100 includes an aftertreatment (AT) system 136 that includes a diesel oxidation catalyst (DOC) 138, a diesel particulate filter (DPF) 140, an aftertreatment (AT) heater 142, and a selective catalytic reduction (SCR) 144. In an exemplary embodiment, the AT heater 142 is optionally included in the AT system 136 to increase the temperature of the exhaust gas provided to the SCR 144 within the AT system 136. It should be noted that the AT heater 142 can include one or more electric heaters that are distributed at various positions at, on, within, or upstream of the SCR 144 or other catalytic elements of the AT system 136.

[0014] System 100 includes an electronic control system (ECS) 130. In the illustrated embodiment, ECS 130 includes an engine control unit (ECU) 132, an aftertreatment control unit (ACU) 133, a heater control unit (HCU) 134, and a powertrain control unit (PSCU) 135, which are operatively communicatively coupled to each other via one or more data links 131, and the one or more data links may include one or more controller area networks (CAN) and / or other types of data links. System 100 may include a plurality of other control units and controllers, as would be appreciated by those skilled in the art benefiting from and having insight into the present disclosure.

[0015] ECU 132 is operatively communicatively coupled to the actuators, controllers, devices, sensors, and / or other components of system 100 (including, for example, many of the foregoing features of system 100) and is configured and operable to control the operation of these components and / or receive inputs from these components.

[0016] HCU 134 is operatively coupled to the AT heater 142 and is configured and operable to control the operation of the AT heater and / or receive inputs from the AT heater. It should be understood that various communication hardware and protocols may be utilized to implement, such as one or more controller area networks (CAN) or other communication components.

[0017] PSCU 135 is operatively communicatively coupled to the power system of system 100 (such as, for example, a motor generator system, a battery system, or other types of power systems) and is configured and operable to control the operation of the power system and / or receive inputs from the power system.

[0018] ECU 132, ACU 133, HCU 134, PSCU 135, and other components of ECS 130 may include one or more programmable controllers of the solid-state integrated circuit type, as well as one or more non-transitory memory media configured to store instructions executable by the one or more microcontrollers. For the purposes of this application, the term "controller" should be understood to also encompass microcontrollers, microprocessors, application specific integrated circuits (ASICs), other types of integrated circuit processors, and combinations thereof.

[0019] The ECU 132, ACU 133, HCU 134, PSCU 135, and other components of the ECS 130 can be implemented in any of a variety of ways that combine or distribute control functions in various ways over one or more control units. The ECS 130 can execute operational logic that defines various control, management, and / or regulation functions. The operational logic can be in the form of dedicated hardware (such as a hardwired state machine), an analog computing machine, programming instructions, and / or different forms that would occur to those skilled in the art. The ECS 130 can be provided as a single component or a collection of operatively coupled components; and can include digital circuitry, analog circuitry, or a hybrid combination of both types. When in the form of multiple components, the ECS 130 can have one or more components that are remotely located in a distributed arrangement relative to other components. The ECS 130 can include multiple processing units that are arranged to operate independently in a pipeline processing arrangement, a parallel processing arrangement, etc. It should also be understood that the ECS 130 and / or any of its constituent components can include one or more signal regulators, modulators, demodulators, arithmetic logic units (ALUs), central processing units (CPUs), limiters, oscillators, control clocks, amplifiers, signal regulators, filters, format converters, communication ports, clamping circuits, delay devices, memory devices, analog-to-digital (A / D) converters, digital-to-analog (D / A) converters, and / or different circuits or components that would occur to those skilled in the art for performing the desired communications.

[0020] The ECU 132, ACU 133, HCU 134, PSCU 135, and other components of the ECS 130 can include one or more non-transitory memory devices configured to store instructions in a memory that can be read and executed by a controller to control the operation of the engine 102 as described herein. Certain control operations described herein include operations for determining one or more parameters. The ECU 132, ACU 133, HCU 134, PSCU 135, and other components of the ECS 130 can be configured to determine in a variety of ways and can perform determination actions in a variety of ways, such as by calculating or operating on values, obtaining values from a lookup table or using a lookup operation, receiving values from a data link or network communication, receiving an electronic signal indicative of a value (e.g., a voltage, frequency, current, or pulse width modulation (PWM) signal), receiving a parameter indicative of a value, reading a value from a memory location on a computer-readable medium, receiving a value as a runtime parameter, and / or by receiving values that can be used to calculate the interpreted parameter, and / or by referencing a default value that is interpreted as a parameter value.

[0021] Reference Figure 2, showing certain aspects of an exemplary electronic control system (ECS) 230. In the example shown, ECS 230 includes a first electronic control unit configured and provided in the form of a heater control unit (HCU) 234. In the example shown, ECS 230 also includes a second electronic control unit configured and provided in the form of an engine control module (ECU) 232. ECS 230 also includes a third electronic control unit configured and provided in the form of a power system control unit (PSCU) 219.

[0022] In the example shown, HCU 234 is configured and provided with two output channels. The first output channel of HCU 234 is configured to drive heater 242 using power from a power source (PS) 220 and a power converter 236, the power converter being operably coupled to the power source 220 and configured to receive power from the power source to selectively power the load of heater 242. The second output channel of HCU 234 is configured to drive heater 262 using power from power source 220 and power converter 266, the power converter being operably coupled to power source 220 and configured to receive power from the power source to selectively power the load of heater 262.

[0023] PSCU 219 is configured to and operable to control the operation of power source 220. Power source 220 can be configured and provided in a variety of forms, including for example a battery-based power source, an alternator or generator-based power source, a power system of a battery and an alternator or generator-based power source, or other types of power sources as would be appreciated and understood by those skilled in the art benefiting from and having insight into the present disclosure. In some embodiments, the power source can be configured and provided as a 48 VDC power source.

[0024] The ECU 232 is configured to send communications to and receive communications from the HCU 234 via one or more data links 210, which may be configured as and set up as, for example, one or more Controller Area Networks (CANs) or one or more other types of data links. In some embodiments, the ECU 232, the HCU 234, and the PSCU 219 may operate communicatively with a common data link (e.g., a common CAN) of the one or more data links 210 and may be configured to and operable to communicate with each other via the common data link. In some embodiments, the one or more data links 210 may include a first data link (e.g., a first CAN) and a second data link (e.g., a second CAN). In some such embodiments, the ECU 232 and the HCU 234 may operate communicatively with the first data link and may be configured to and operable to communicate with each other via the first data link. In some such embodiments, the ECU 232 and the PSCU 219 may operate communicatively with the second data link and may be configured to and operable to communicate with each other via the second data link.

[0025] One or more sensors 246 are configured to sense one or more operating characteristics of the load of the heater 242 or one or more operating characteristics associated with the load of the heater. In the example shown, the one or more sensors 246 include one or more voltage sensors configured to sense the voltage of the load of the heater 242 or the voltage associated with the load of the heater; and one or more current sensors configured to sense the current of the load of the heater 242 or the current associated with the load of the heater. In some embodiments, the one or more sensors 246 may include additional sensors, such as one or more temperature sensors configured to sense the temperature of the load of the heater 242 or the temperature associated with the load of the heater.

[0026] One or more sensors 256 are configured to sense one or more operating characteristics of the load of the heater 262 or one or more operating characteristics associated with the load of the heater. In the example shown, the one or more sensors 256 include one or more voltage sensors configured to sense the voltage of the load of the heater 262 or the voltage associated with the load of the heater; and one or more current sensors configured to sense the current of the load of the heater 262 or the current associated with the load of the heater. In some embodiments, the one or more sensors 256 may include additional sensors, such as one or more temperature sensors configured to sense the temperature of the load of the heater 262 or the temperature associated with the load of the heater.

[0027] The outputs of one or more sensors 246 associated with the load of heater 242 and the outputs of one or more sensors 256 associated with the load of heater 262 can be provided as or used to determine the setpoint determination logic 239.

[0028] The HCU 234 includes a setpoint determination logic 239, which can be implemented in combination with a microcontroller, a memory, and / or other control structures of the HCU 234. In one aspect, the setpoint determination logic 239 is configured to determine the heater load resistance. In some embodiments, the setpoint determination logic 239 is configured to determine the heater load resistance in response to the measured output voltage and the measured output current of the HCU 234, for example, by dividing the measured output voltage by the measured output current.

[0029] In another aspect, the setpoint determination logic 239 is configured to determine the target HCU output current. In some embodiments, the setpoint determination logic 239 is configured to determine the target HCU output current in response to the commanded power output of the HCU 234 and the heater load resistance. In some forms, the setpoint determination logic 239 can be configured to determine the target HCU output current by calculating the square root of the ratio of the commanded power output to the heater load resistance (Iout_target = SQRT(P_command / R_load)). In some forms, the setpoint determination logic 239 can be configured to use a look-up table (LUT) to determine the target HCU output current, the look-up table being configured with target HCU output currents empirically determined for corresponding commanded power output values and heater load resistance values.

[0030] In another aspect, the setpoint determination logic 239 is configured to determine the target HCU output voltage. In some embodiments, the setpoint determination logic 239 can be configured to determine the target HCU output voltage in response to the commanded power output and the target HCU output current, for example, by taking the ratio of the commanded power output of the HCU to the target HCU output current or dividing the commanded power output of the HCU by the target HCU output current (Vout_target = P_command / Iout_target).

[0031] In another aspect, the setpoint determination logic 239 is configured to determine the HCU voltage drop. In some embodiments, the setpoint determination logic 239 may be configured to determine the HCU voltage drop in response to the measured input voltage of the HCU 234 and the measured output voltage of the HCU 234. In some embodiments, the setpoint determination logic 239 may be configured to determine the HCU voltage drop in response to one or more predetermined values of the HCU 234. In some embodiments, the setpoint determination logic 239 may be configured to determine the HCU voltage drop in response to one or more predetermined values of the HCU 234, and the one or more predetermined values may be adjusted or scaled in response to one or more operating parameters of the HCU 234 (e.g., the power converter duty cycle).

[0032] In another aspect, the setpoint determination logic 239 is configured to determine a setpoint parameter, e.g., the voltage setpoint of the power supplied by the PSCU 219 to the HCU 234, which may also be regarded as the input voltage setpoint (Vin_set). In some embodiments, the setpoint determination logic 239 may be configured to determine the setpoint parameter in response to the target HCU output voltage, the HCU voltage drop, and the optimal power converter duty cycle, e.g., by dividing the target HCU output voltage by the sum of the HCU voltage drop and the optimal power converter duty cycle (Vin_set = Vtarget / DC_optimal + Vhcu_vdrop). The optimal power converter duty cycle may include, for example, the optimal DC-DC converter duty cycle, which may be a predetermined value or an adjusted or scaled value determined in response to one or more operating parameters of the HCU 234.

[0033] In some embodiments, the setpoint parameter determined by the setpoint determination logic 239 may be transmitted by the HCU 234 and provided to the ECU 232, and further may be transmitted by the ECU 232 and provided to the PSCU 219. In some embodiments, the setpoint parameter determined by the setpoint determination logic 239 may be transmitted by the HCU 234 and provided to the PSCU 219. In an exemplary embodiment, the PSCU 219 receives the setpoint parameter in the foregoing or other manner and adjusts the variable voltage supplied to the HCU 234 in response to the setpoint parameter.

[0034] In the illustrated embodiment, the power converter 236 is configured as and set up as a DC-DC power converter, which is operably coupled to the power supply 220 and configured to receive DC power from the power supply, and the power supply can provide such power from one or more power storage and / or power generation systems. In some forms, the power converter 236 can be configured and provided in the form of a buck converter (such as an interleaved buck converter). In other embodiments, the power converter 236 can be configured as and set up as another type of DC-DC converter. In other embodiments, the power converter 236 can be configured as and set up as an AC-DC power converter, which is operably coupled to the power supply 220 and configured to receive AC power from the power supply.

[0035] In the illustrated embodiment, the power converter 266 is configured as and set up as a DC-DC power converter, which is operably coupled to the power supply 220 and configured to receive DC power from the power supply, and the power supply can provide such power from one or more power storage and / or power generation systems. In some forms, the power converter 266 can be configured and provided in the form of a buck converter (such as an interleaved buck converter). In other embodiments, the power converter 266 can be configured as and set up as another type of DC-DC converter. In other embodiments, the power converter 266 can be configured as and set up as an AC-DC power converter, which is operably coupled to the power supply 220 and configured to receive AC power from the power supply.

[0036] Combined with Figure 2 The architectures and topologies described can be used and provided in a variety of forms. Some such forms can include a first power converter channel (such as the channel of the power converter 236 configured to drive a first heater (such as heater 242)) and a second power converter channel (such as the channel of the power converter 266 configured to drive a second heater (such as heater 262)). Some such forms can include different arrangements of multi-channel power converters and heater loads, including the following examples. In some embodiments, for example, some such forms can include a single power converter channel configured to drive two or more heaters. In some embodiments, for example, some such forms can include two power converter channels configured to drive a single heater. In other exemplary embodiments, some such forms can include a single channel configured to drive two heaters in parallel. Additionally, in other exemplary embodiments, some such forms can include a single channel configured to drive two heaters in series.

[0037] Refer to Figure 3, which shows a flowchart depicting certain aspects of an exemplary control process 300 (also referred to herein as process 300). Process 300 is described in connection with ECU 232, HCU 234, and PSCU 219. It should be understood that process 300 can be implemented and executed in connection with various other electronic control units and electronic control system components.

[0038] Process 300 begins at start operation 302 and proceeds to operation 304, where the heater load resistance (R_load) is determined, for example, in response to the measured output voltage and measured output current of the HCU. Operation 304 can utilize techniques, calculations, and / or operations described above in connection with the setpoint determination logic 239.

[0039] Process 300 continues from operation 304 to operation 306, where the target HCU output current (Iout_target) is determined by the commanded power output and the heater load resistance (R_load). Operation 306 can utilize techniques, calculations, and / or operations described above in connection with the setpoint determination logic 239.

[0040] Process 300 continues from operation 306 to operation 308, where the target HCU output voltage (Vout_target) is determined by the commanded power output (P_command) and the target HCU output current (Iout_target). Operation 308 can utilize techniques, calculations, and / or operations described above in connection with the setpoint determination logic 239.

[0041] Process 300 continues from operation 308 to operation 310, where the HCU voltage drop (Vhcu_drop) is determined by measuring the input voltage and output voltage of the HCU in real time. For example, the HCU voltage drop (Vhcu_drop) can be the forward voltage drop across the HCU from input to output. Operation 308 can utilize techniques, calculations, and / or operations described above in connection with the setpoint determination logic 239.

[0042] Process 300 continues from operation 310 to operation 312, where the input voltage setpoint (Vin_set) is determined. In some embodiments, the input voltage setpoint (Vin_set) can be a setpoint parameter determined by the target HCU output voltage (Vout_target), the HCU voltage drop (Vhcu_drop), and the optimal duty cycle of the HCU (DChcu_opt). Operation 312 can utilize techniques, calculations, and / or operations described above in connection with the setpoint determination logic 239.

[0043] Process 300 continues from operation 312 to operation 314, where the input voltage setpoint (Vin_set) is transmitted by the HCU. For example, the setpoint parameter may be transmitted by the HCU to the PSCU, or may be transmitted by the HCU to the ECU, and then by the ECU to the PSCU.

[0044] Process 300 continues from operation 314 to operation 316, where the input voltage setpoint (Vin_set) is received by the PSCU. Process 300 continues from operation 316 to operation 318, where the PSCU sets (e.g., adjusts or maintains) its variable output voltage in response to the received input voltage setpoint (Vin_set). The variable output voltage is then provided as the input voltage to the HCU.

[0045] As shown by this detailed description, the present disclosure contemplates multiple and various embodiments, including but not limited to the following exemplary embodiments.

[0046] A first exemplary embodiment is a system that includes: an exhaust aftertreatment system that includes a heater configured to provide heat to a catalyst; a heater control unit (HCU) configured to supply power to the heater; and a power supply control unit (PSCU) configured to supply power to the HCU at a variable voltage, where the HCU is configured to determine a setpoint parameter that varies in response to a change in the power output of a command of the HCU for driving the heater, the PSCU is configured to receive the setpoint parameter and adjust the variable voltage supplied to the HCU in response to the setpoint parameter, and the adjustment of the setpoint parameter is effective to optimize the efficiency of the HCU during an operation of supplying the command power output to the heater.

[0047] A second exemplary embodiment includes the features of the first exemplary embodiment, where the HCU is configured to receive the command power output from an engine control unit (ECU).

[0048] A third exemplary embodiment includes the features of the first exemplary embodiment, where the HCU is configured to determine a heater load resistance in response to a measured output voltage of the HCU and a measured output current of the HCU.

[0049] A fourth exemplary embodiment includes the features of the third exemplary embodiment, where the HCU is configured to determine a target output current in response to the command power output and the heater load resistance, and determine a target output voltage in response to the command power output and the target output current.

[0050] The fifth exemplary embodiment includes the features of the fourth exemplary embodiment, wherein the HCU is configured to determine the voltage drop across the HCU in response to at least one of (a) an input voltage measurement and an output voltage measurement and (b) a predetermined value.

[0051] The sixth exemplary embodiment includes the features of the fifth exemplary embodiment, wherein the HCU is configured to determine the setpoint parameter in response to the voltage target, the voltage drop across the HCU, and the optimal power converter duty cycle.

[0052] The seventh exemplary embodiment includes the features of the second exemplary embodiment, wherein the ECU is configured to communicate with the HCU via a first controller area network and is configured to communicate with the PSCU via a second controller area network.

[0053] The eighth exemplary embodiment includes the features of the first exemplary embodiment, wherein the PSCU includes a motor generator unit (MGU).

[0054] The ninth exemplary embodiment includes the features of the second exemplary embodiment, wherein the HCU is configured to provide the setpoint parameter to the ECU, and the ECU is configured to provide the setpoint parameter to the HCU.

[0055] The tenth exemplary embodiment includes the features of the first exemplary embodiment, wherein the HCU is configured to supply power to a plurality of heaters.

[0056] The eleventh exemplary embodiment is a method of operating an exhaust aftertreatment system, the exhaust aftertreatment system including a heater configured to provide heat to a catalyst, the method including: operating a heater control unit (HCU) to supply power to the heater; operating a power supply control unit (PSCU) to supply power to the HCU at a variable voltage; using the HCU to determine a setpoint parameter that varies in response to a change in the power output of a command of the HCU to drive the heater; using the PSCU to receive the setpoint parameter; and using the PSCU to adjust the variable voltage supplied to the HCU in response to the setpoint parameter, and the adjustment of the setpoint parameter is effective to optimize the efficiency of the HCU during operation of supplying the commanded power output to the heater.

[0057] The twelfth exemplary embodiment includes the features of the eleventh exemplary embodiment, which includes the HCU receiving the commanded power output from an engine control unit (ECU).

[0058] The thirteenth exemplary embodiment includes the features of the eleventh exemplary embodiment, which includes the HCU determining the heater load resistance in response to the measured output voltage and the measured output current of the HCU.

[0059] The fourteenth exemplary embodiment includes the features of the thirteenth exemplary embodiment, which includes the HCU determining a target output current in response to the commanded power output and the heater load resistance, and determining a target output voltage in response to the commanded power output and the target output current.

[0060] The fifteenth exemplary embodiment includes the features of the fourteenth exemplary embodiment, which includes the HCU determining the voltage drop across the HCU in response to at least one of (a) the input voltage measurement and the output voltage measurement and (b) a predetermined value.

[0061] The sixteenth exemplary embodiment includes the features of the fifteenth exemplary embodiment, which includes the HCU determining the set point parameter in response to the voltage target, the voltage drop across the HCU, and the optimal power converter duty cycle.

[0062] The seventeenth exemplary embodiment includes the features of the twelfth exemplary embodiment, which includes the ECU communicating with the HCU via a first controller area network and communicating with the PSCU via a second controller area network.

[0063] The eighteenth exemplary embodiment includes the features of the eleventh exemplary embodiment, wherein the PSCU includes a motor generator unit (MGU).

[0064] The nineteenth exemplary embodiment includes the features of the twelfth exemplary embodiment, which includes the HCU providing the set point parameter to the ECU and the ECU providing the set point parameter to the HCU.

[0065] The twentieth exemplary embodiment includes the features of the eleventh exemplary embodiment, which includes the HCU supplying power to a plurality of heaters.

[0066] It should be understood that terms such as "non-transitory memory", "non-transitory storage medium", and "non-transitory storage device" refer to various types of devices and storage media that can be configured to store information that can be read or executed by a processor or other components of a computer system, such as data or instructions, and such terms include and encompass a single or solitary device or medium that stores such information, multiple devices or media across which or in which corresponding portions of such information are stored, and multiple devices or media across which or in which multiple copies of such information are stored.

[0067] It should be understood that when used in conjunction with a control method or process, an electronic control system or controller, an electronic control, or the components or operations described above, terms such as "determine", "determined", "determining", etc. inclusively refer to a plurality of actions, configurations, devices, operations, and techniques, including but not limited to the calculation or computation of a parameter or value, obtaining a parameter or value from a look-up table or using a look-up operation, receiving a parameter or value from a data link or network communication, receiving an electronic signal indicating a parameter or value (e.g., a voltage, frequency, current, or pulse width modulation (PWM) signal), receiving a sensor output indicating a parameter or value, receiving other outputs or inputs indicating a parameter or value, reading a parameter or value from a memory location on a computer-readable medium, receiving a parameter or value as a runtime parameter, and / or by receiving a parameter or value that can be used to calculate an interpretation, and / or by referring to a default value that is interpreted as a parameter value.

[0068] Although the exemplary embodiments of the present disclosure have been shown and described in detail in the drawings and the foregoing description, this is considered to be illustrative rather than restrictive in nature. It should be understood that only certain exemplary embodiments have been shown and described, and all changes and modifications that fall within the spirit of the claimed invention are protected. It should be understood that although the use of words such as "preferred", "preferably", "preferred", or "more preferred" as used in the foregoing description indicates that the features so described may be more desirable, they may not be necessary and embodiments without such words are contemplated to be within the scope of the present invention, which is defined by the appended claims. When reading the claims, it is intended that when words such as "a", "an", "at least one", or "at least a portion" are used, the claims are not intended to be limited to only one item unless the claims expressly state the contrary. When the language "at least a portion" and / or "a portion" is used, the item may include a portion and / or the whole item unless there is an express contrary indication.

Claims

1. A system comprising: an exhaust aftertreatment system including a heater configured to provide heat to a catalyst; a heater control unit (HCU) configured to supply power to the heater; and a power supply control unit (PSCU) configured to supply power to the HCU at a variable voltage, wherein the HCU is configured to determine a set point parameter that changes in response to a change in a commanded power output of the HCU for driving the heater, the PSCU is configured to receive the set point parameter and adjust the variable voltage supplied to the HCU in response to the set point parameter, and the adjustment of the set point parameter is effective to optimize the efficiency of the HCU during operation of supplying the commanded power output to the heater.

2. The system of claim 1, wherein the HCU is configured to receive the commanded power output from an engine control unit (ECU). 3 . The system of claim 1 , wherein the HCU is configured to determine a heater load resistance in response to a measured output voltage of the HCU and a measured output current of the HCU.

4. The system of claim 3, wherein the HCU is configured to determine a target output current in response to the commanded power output and the heater load resistance, and to determine a target output voltage in response to the commanded power output and the target output current.

5. The system of claim 4, wherein the HCU is configured to determine a voltage drop across the HCU in response to at least one of (a) an input voltage measurement and an output voltage measurement and (b) a predetermined value. 6 . The system of claim 5 , wherein the HCU is configured to determine the set point parameter in response to the voltage target, the voltage drop across the HCU, and an optimal power converter duty cycle.

7. The system of claim 2, wherein the ECU is configured to communicate with the HCU via a first controller area network and is configured to communicate with the PSCU via a second controller area network.

8. The system of claim 1, wherein the PSCU comprises a motor generator unit (MGU).

9. The system of claim 2, wherein the HCU is configured to provide the set point parameter to the ECU, and the ECU is configured to provide the set point parameter to the HCU.

10. The system of claim 1, wherein the HCU is configured to supply power to a plurality of heaters.

11. A method of operating an exhaust aftertreatment system, the exhaust aftertreatment system comprising a heater configured to provide heat to a catalyst, the method comprising: operating a heater control unit (HCU) to supply power to the heater; operating a power supply control unit (PSCU) to supply power to the HCU at a variable voltage; determining, with the HCU, a set point parameter that varies in response to a change in a commanded power output of the HCU for driving the heater; receiving the set point parameter using the PSCU; The variable voltage supplied to the HCU is adjusted using the PSCU in response to the set point parameter, and the adjustment of the set point parameter is effective to optimize the efficiency of the HCU during operation of supplying the commanded power output to the heater.

12. The method of claim 11, comprising the HCU receiving the commanded power output from an engine control unit (ECU).

13. The method of claim 11, comprising the HCU determining a heater load resistance in response to a measured output voltage of the HCU and a measured output current of the HCU.

14. The method of claim 13, comprising the HCU determining a target output current in response to the commanded power output and the heater load resistance, and determining a target output voltage in response to the commanded power output and the target output current.

15. The method of claim 14, comprising the HCU determining a voltage drop across the HCU in response to at least one of (a) an input voltage measurement and an output voltage measurement and (b) a predetermined value.

16. The method of claim 15, comprising the HCU determining the set point parameter in response to the voltage target, the voltage drop across the HCU, and an optimal power converter duty cycle.

17. The method of claim 12, comprising the ECU communicating with the HCU via a first controller area network and communicating with the PSCU via a second controller area network.

18. The method of claim 11, wherein the PSCU comprises a motor generator unit (MGU).

19. The method of claim 12, comprising the HCU providing set point parameters to the ECU and the ECU providing the set point parameters to the HCU.

20. The method of claim 11, comprising the HCU supplying power to a plurality of heaters.

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