Accurate dust filtration detection device and system for heavy truck filter production
By using a multi-sensor fusion array and digital twin monitoring technology, the intake resistance, filtration efficiency, and dust storage capacity of heavy-duty truck filters can be monitored and controlled in real time, solving the problem of insufficient accuracy in dust detection in existing technologies and realizing accurate detection and automated testing throughout the entire life cycle.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-21
AI Technical Summary
Existing heavy-duty truck filter dust detection systems cannot monitor dust concentration in real time, resulting in insufficient accuracy in calculating filtration efficiency. They are also susceptible to affecting test results due to dust agglomeration and pipeline residue.
By employing a multi-dimensional intelligent sensing module, an adaptive dynamic flow control module, and a digital twin monitoring module, a multi-sensor fusion array is constructed to monitor intake resistance, filtration efficiency, and ash storage capacity in real time. Through PID regulation and high-speed solenoid valve switching of nozzle combinations, closed-loop data control is achieved, and the digital twin model performs real-time diagnosis and prediction.
It enables precise testing throughout the entire lifecycle of heavy-duty truck filters, improves the accuracy and automation of filtration efficiency calculation, reduces human error, and ensures consistency of test conditions and real-time data feedback.
Smart Images
Figure CN121898762A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of detection technology, specifically to a precision dust detection device and system for heavy-duty truck filter production. Background Technology
[0002] Heavy-duty truck engines have extremely high requirements for air intake cleanliness. The filtration efficiency, intake resistance, and dust storage capacity of heavy-duty truck filters directly affect engine life and power performance. According to standards such as GB / T 28949-2012 "Performance Test of Intake Air Filters for Internal Combustion Engines and Air Compressors" and JB / T 9755.5-2013 "Test Methods for Air Filters for Internal Combustion Engines", heavy-duty truck filters must pass dust filtration performance tests before leaving the factory. Existing dust detection systems for heavy-duty truck filters rely on the dust addition rate for dust concentration estimation, which cannot monitor the actual dust concentration entering the filter in real time. Dust agglomeration and pipeline residue can easily lead to concentration deviations, thus affecting the accuracy of filtration efficiency calculations. To address this, we propose a precise dust detection device and system for heavy-duty truck filter production. Summary of the Invention
[0003] The purpose of this invention is to provide a precise dust detection device and system for heavy-duty truck filter production.
[0004] To achieve the above objectives, the present invention provides the following technical solution: a precision dust detection system for heavy-duty truck filter production, comprising full-process automation and precise data closed-loop, the precision dust detection system for heavy-duty truck filter production further comprising the following modules; The multi-dimensional intelligent sensing module constructs a multi-sensor fusion array to monitor resistance and efficiency parameters, aligns and fuses data timestamps, and forms an integrated performance profile of the filter. The adaptive dynamic flow control module consists of a parallel air path composed of critical flow venturi nozzles. It switches nozzles based on intake resistance to stabilize volumetric flow rate and ensure constant test conditions for filtration efficiency throughout the entire lifespan. The closed-loop intelligent powder addition module adjusts the feed motor with PID control according to the test plan and real-time concentration and pressure difference. It maintains a constant dosage during the efficiency stabilization period and adjusts the dosage during the decline period, realizing a closed-loop data system of perception, decision-making and execution. The digital twin monitoring module establishes a physical correspondence model, receives and visualizes data, and provides real-time diagnosis and lifespan prediction. As the core brain, it issues instructions to form a continuous optimization closed loop.
[0005] As a further aspect of the present invention: the multi-dimensional intelligent sensing module constructs a multi-sensor fusion intelligent sensing array to capture the dynamic changes of key parameters such as air intake resistance, filtration efficiency, and ash storage capacity during the testing process. Laser particle counters and differential pressure sensors are deployed upstream and downstream of the filter, respectively, to calculate the filtration efficiency of particles of different sizes and the pressure drop upstream and downstream of the filter in real time, thereby realizing transient and cumulative analysis of filtration efficiency. At the same time, the overall mass change of the filter is monitored in real time by a weighing sensor, providing direct data support for ash storage capacity assessment. All sensor data are timestamped and fused through a computer data acquisition and processing system to form a multi-dimensional and integrated performance profile.
[0006] As a further aspect of the present invention: the adaptive dynamic flow control module constructs a parallel air path group composed of critical flow Venturi nozzles, with each nozzle serving as a standard volumetric flow meter. Based on the real-time feedback of inlet resistance data from the multi-dimensional intelligent sensing module, the adaptive dynamic flow control module intelligently switches different nozzle combinations via a high-speed solenoid valve to control the volumetric flow rate in the test pipeline to remain stable within the range of 0.99x-1.01x, where x represents the set value of the volumetric flow rate. This is unaffected by changes in filter resistance due to dust accumulation, and the dynamic flow control achieves constant test conditions throughout the entire lifespan filtration efficiency test.
[0007] As a further aspect of the present invention: the closed-loop intelligent dust addition module, based on the test plan and real-time feedback of upstream and downstream dust concentration and pressure difference data, dynamically adjusts the speed and start / stop of the feeding motor through PID to achieve on-demand dust addition. During the efficiency stabilization phase, a constant dosage is used, and during the efficiency decline phase, adaptive adjustment is made to accelerate testing and perform fine capture, thereby realizing a data closed loop of perception, decision-making, and execution.
[0008] As a further aspect of the present invention: the digital twin monitoring module constructs a digital twin model corresponding to the physical detection system. The digital twin model receives all data streams from the aforementioned three modules in real time, performs a visualized three-dimensional dynamic display, and realizes real-time diagnosis, process backtracking, and prediction of filter performance through the built-in physical model and data-driven algorithm. Based on the real-time pressure difference and powder addition amount, the digital twin model predicts the remaining ash storage capacity and expected life of the filter, backtracks the flow field and dust distribution state of the filter, and assists in failure analysis. The digital twin extends the one-time physical test into a data asset for repeated analysis and in-depth mining, realizing in-depth perception, precise control, and intelligent insight of the entire process of multi-parameter testing of air intake resistance, filtration efficiency, and ash storage capacity.
[0009] As a further aspect of the present invention: the digital twin monitoring module, acting as the core brain, issues commands to the adaptive dynamic flow control module and the closed-loop intelligent dust filling module according to the test plan. The adaptive dynamic flow control module maintains constant flow through the critical flow venturi nozzle group, while providing real-time flow data to the closed-loop intelligent dust filling module to accurately calculate and dynamically adjust the dust injection amount. The multi-dimensional intelligent sensing module, acting as the sensory nerve of the system, collects key data on the filter's differential pressure, efficiency, and weight in real time and feeds them back to the digital twin. By comparing the real-time data of the physical entity and the virtual model, the digital twin continuously optimizes and issues new control commands, forming a continuous optimization closed loop of perception, decision-making, execution, and verification, thereby achieving accurate, adaptive, and intelligent testing of filter performance throughout its entire life cycle.
[0010] In addition, the present invention also provides a dust precision detection device for heavy truck filter production, including a bottom cover and a barrel body. A safety filter element is provided on the inner wall of the barrel body, and a main filter element is slidably connected to the side of the safety filter element. An outlet elbow is connected to the side of the barrel body.
[0011] As a further aspect of the present invention: a handle is installed on the side of the barrel, and the barrel and the bottom cover are engaged by the handle.
[0012] As a further aspect of the present invention: a sensor connector is connected to the side of the outlet bend, a dust discharge valve is connected to the side of the bottom cover, and the interior of the outlet bend is connected to the interior of the barrel.
[0013] Compared with the prior art, the beneficial effects of the present invention by adopting the above technical solution are as follows: 1. This invention simultaneously captures three core parameters: air intake resistance, filtration efficiency, and dust storage capacity, rather than monitoring only resistance or efficiency. This allows for the creation of a performance profile of the filter throughout its entire lifecycle, avoiding misjudgments of performance due to missing parameters. It uses real-time direct measurement instead of indirect calculation, and a laser particle counter to count the concentration of dust particles of different sizes upstream and downstream in real time, directly calculating the filtration efficiency. 2. This invention uses a critical flow venturi nozzle assembly as a standard volumetric flow meter. Based on the real-time inlet resistance, the nozzle combination can be intelligently switched via a high-speed solenoid valve to stabilize the pipeline flow rate within ±1% of the set value. This is unaffected by changes in filter element resistance due to dust accumulation. This means that all test data for the filter element from its initial state to its failure state are based on the same flow conditions, significantly improving data comparability. The nozzle assembly can adapt to the entire stage of the filter element from initial low resistance to failure high resistance. There is no need for manual replacement of the flow meter or adjustment of the valve, reducing human error and improving the degree of automation in testing.
[0014] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description
[0015] Figure 1 A flowchart illustrating a precision dust detection system for heavy-duty truck filter production. Figure 2 This is a schematic diagram of an embodiment of the present invention; Figure 3 This is a schematic diagram of the outlet bend in an embodiment of the present invention; Figure 4 This is a schematic diagram of the sensor connector in an embodiment of the present invention; Figure 5 This is a schematic diagram of the barrel body in an embodiment of the present invention.
[0016] In the diagram: 1. Bottom cover; 2. Handle; 3. Main filter element; 4. Safety filter element; 5. Barrel body; 6. Outlet elbow; 7. Dust discharge valve; 8. Sensor connector. Detailed Implementation
[0017] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be noted that the description of these embodiments is for the purpose of helping to understand the present invention, but does not constitute a limitation of the present invention.
[0018] Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.
[0019] Please see the appendix Figure 1 The present invention provides a precision dust detection system for heavy-duty truck filter production, comprising full-process automation and precise data closed-loop; Example 1: The dust detection system for heavy-duty truck filter production also includes the following modules; The multi-dimensional intelligent sensing module constructs a multi-sensor fusion array to monitor resistance and efficiency parameters, aligns and fuses data timestamps, and forms an integrated performance profile of the filter. The adaptive dynamic flow control module consists of a parallel air path composed of critical flow venturi nozzles. It switches nozzles based on intake resistance to stabilize volumetric flow rate and ensure constant test conditions for filtration efficiency throughout the entire lifespan. The closed-loop intelligent powder addition module adjusts the feed motor with PID control according to the test plan and real-time concentration and pressure difference. It maintains a constant dosage during the efficiency stabilization period and adjusts the dosage during the decline period, realizing a closed-loop data system of perception, decision-making and execution. The digital twin monitoring module establishes a physical correspondence model, receives and visualizes data, diagnoses and predicts lifespan in real time, and acts as the core brain to issue instructions, forming a continuous optimization closed loop. Specifically, the system uses a digital twin monitoring module as its core, linking three major modules: multi-dimensional perception, adaptive flow control, and closed-loop follower acquisition, to form a dynamic optimization closed loop. The principle is as follows: The multi-dimensional intelligent sensing module collects core parameters in real time, capturing the dynamic changes in the three core performance parameters of the filter: air intake resistance, filtration efficiency, and ash storage capacity. Laser particle counters (to measure the concentration of particles of different sizes and calculate filtration efficiency) and differential pressure sensors (to measure the pressure drop between upstream and downstream and calculate air intake resistance) are deployed upstream and downstream of the filter. Weighing sensors are deployed throughout the filter (to measure mass change and calculate ash storage capacity). All sensor data are timestamped and fused through a computer system to eliminate data delay and bias, forming an integrated performance profile of resistance, efficiency, and ash storage capacity, providing real-time data support for subsequent decision-making. The adaptive dynamic flow control module ensures constant test conditions and solves the problem of unstable volumetric flow rate in the test pipeline when the resistance changes due to filter dust accumulation. It ensures consistent test conditions throughout the entire life cycle. The parallel air path is composed of critical flow Venturi nozzle groups (each nozzle is a standard volumetric flow meter, and different nozzles correspond to different flow ranges). It receives real-time air intake resistance data from the multi-dimensional sensing module and intelligently switches the nozzle combination through a high-speed solenoid valve (e.g., when the resistance increases, switch to a high-flow nozzle, and when the resistance decreases, switch to a low-flow nozzle). Finally, it stabilizes the volumetric flow rate in the pipeline at the set value and is not affected by the filter dust accumulation state. The closed-loop intelligent dust dosing module simulates actual dust filtration scenarios on demand, dynamically adjusting the dust injection amount according to the test stage. This ensures test accuracy while avoiding dust waste or excessively long test cycles. It inputs the test plan (such as target dust concentration and test stage) and receives upstream and downstream dust concentration and pressure difference data from multi-dimensional sensing modules. It adopts constant dosage dust dosing to simulate the dust load when the filter is working normally, adaptively increasing the dust dosing amount to accelerate the capture of the filter performance degradation inflection point (such as a sudden drop in efficiency or a sudden increase in resistance). This forms a closed loop of sensing concentration / pressure difference, deciding on the dust dosing amount, and executing motor start / stop / speed adjustment to ensure that the dust injection matches the filter state. The digital twin monitoring module is responsible for decision-making and optimization. It constructs a 1:1 digital twin model corresponding to the physical detection system, receives all data streams from the first three modules in real time, and dynamically displays the flow field and dust distribution of the filter in three dimensions. It diagnoses performance anomalies (such as excessively high local resistance) in real time. Based on real-time differential pressure and dust addition data, it predicts the filter's remaining dust storage capacity and expected lifespan. If a failure occurs, it can trace back historical data to locate the cause of the failure (such as a sudden drop in efficiency caused by dust of a certain particle size). According to the test plan and real-time data, it sends flow setting instructions to the adaptive flow control module and provides real-time flow data to the closed-loop dust addition module (for accurate calculation of dust injection amount). Finally, it forms a continuous optimization closed loop of perception, decision-making, execution and verification.
[0020] Example 2, please refer to the appendix. Figure 2 -Appendix Figure 5 A precision dust detection device for heavy-duty truck filter production includes a bottom cover 1 and a barrel 5. A safety filter element 4 is installed on the inner wall of the barrel 5. A main filter element 3 is slidably connected to the side of the safety filter element 4. An outlet elbow 6 is connected to the side of the barrel 5. A sensor connector 8 is connected to the side of the outlet elbow 6. A dust discharge valve 7 is connected to the side of the bottom cover 1. The interior of the outlet elbow 6 is connected to the interior of the barrel 5. Specifically, the physical device is a test container for the filter, which works with the system module to collect parameters. The structure and principle are as follows: The inner wall of the barrel 5 is equipped with a safety filter element 4, which is slidably connected to the main filter element 3 on its side. The main filter element 3 is the main filtration component, and the safety filter element 4 is a spare (to prevent dust leakage in case the main filter element 3 is damaged, ensuring the accuracy of the test). The dust-laden airflow to be tested enters from the bottom cover 1 or the inlet of the barrel 5, passes through the main filter element 3 and the safety filter element 4 in sequence, and then flows out from the outlet bend cover 6. The sensor connector 8 on the side of the outlet bend cover 6 is connected to the differential pressure sensor and laser particle counter of the system to collect the parameters of the filtered airflow in real time. The dust discharge valve 7 of the bottom cover 1 can discharge the dust remaining after the test. The handle 2 on the side of the barrel 5 enables quick engagement and disengagement of the bottom cover 1 and the barrel 5, making it convenient to replace the filter test piece. At this point, the entire workflow is completed.
[0021] The terms "front," "back," "left," "right," "top," and "bottom" all refer to the figures in the accompanying drawings. Figure 1 Based on.
[0022] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this invention.
[0023] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments.
[0024] For those skilled in the art, various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and these variations still fall within the protection scope of the present invention.
Claims
1. A precision dust detection system for heavy-duty truck filter production, comprising full-process automation and precise data closed-loop, characterized in that: The precision dust detection system for heavy-duty truck filter production also includes the following modules; The multi-dimensional intelligent sensing module constructs a multi-sensor fusion array to monitor resistance and efficiency parameters, aligns and fuses data timestamps, and forms an integrated performance profile of the filter. The adaptive dynamic flow control module consists of a parallel air path composed of critical flow venturi nozzles. It switches nozzles based on intake resistance to stabilize volumetric flow rate and ensure constant test conditions for filtration efficiency throughout the entire lifespan. The closed-loop intelligent powder addition module adjusts the feed motor with PID control according to the test plan and real-time concentration and pressure difference. It maintains a constant dosage during the efficiency stabilization period and adjusts during the decline period, realizing a closed-loop data system of perception, decision-making and execution. The digital twin monitoring module establishes a physical correspondence model, receives and visualizes data, and provides real-time diagnosis and lifespan prediction. As the core brain, it issues instructions to form a continuous optimization closed loop.
2. The dust detection system for heavy-duty truck filter production according to claim 1, characterized in that: The multi-dimensional intelligent sensing module constructs a multi-sensor fusion intelligent sensing array to capture the dynamic changes of key parameters such as air intake resistance, filtration efficiency, and ash storage capacity during the test process. Laser particle counters and differential pressure sensors are deployed upstream and downstream of the filter, respectively, to calculate the filtration efficiency of particles of different sizes and the pressure drop upstream and downstream of the filter in real time, realizing transient and cumulative analysis of filtration efficiency. At the same time, the overall mass change of the filter is monitored in real time by a weighing sensor, providing direct data support for ash storage capacity assessment. All sensor data are timestamped and fused through a computer data acquisition and processing system to form a multi-dimensional and integrated performance profile.
3. The dust detection system for heavy-duty truck filter production according to claim 2, characterized in that: The adaptive dynamic flow control module constructs a parallel air path group composed of critical flow Venturi nozzles. Each nozzle serves as a standard volumetric flow meter. Based on the real-time feedback of inlet resistance data from the multi-dimensional intelligent sensing module, the adaptive dynamic flow control module intelligently switches different nozzle combinations through a high-speed solenoid valve to control the volumetric flow rate in the test pipeline to remain stable within the range of 0.99x-1.01x, where x represents the set value of the volumetric flow rate. This is unaffected by changes in filter resistance due to dust accumulation. The dynamic flow control achieves constant test conditions throughout the entire lifespan filtration efficiency test.
4. The dust detection system for heavy-duty truck filter production according to claim 3, characterized in that: The closed-loop intelligent dust addition module dynamically adjusts the speed and start / stop of the feeding motor through PID control based on the test plan and real-time feedback of upstream and downstream dust concentration and pressure difference data. This enables on-demand dust addition, using a constant dosage during the efficiency stabilization phase and adaptive adjustment during the efficiency decline phase to accelerate testing and perform precise capture, thus achieving a data closed loop of perception, decision-making, and execution.
5. The dust detection system for heavy-duty truck filter production according to claim 4, characterized in that: The digital twin monitoring module constructs a digital twin model corresponding to the physical testing system. The digital twin model receives all data streams from the aforementioned three modules in real time, performs a visualized three-dimensional dynamic display, and realizes real-time diagnosis, process backtracking, and prediction of filter performance through the built-in physical model and data-driven algorithms. Based on real-time pressure difference and powder addition, the digital twin model predicts the filter's remaining ash storage capacity and expected lifespan, backtracks the filter's flow field and dust distribution state, and assists in failure analysis. The digital twin extends a one-time physical test into a data asset for repeated analysis and in-depth mining, realizing in-depth perception, precise control, and intelligent insight into the entire process of multi-parameter testing of intake resistance, filtration efficiency, and ash storage capacity.
6. The dust detection system for heavy-duty truck filter production according to claim 5, characterized in that: The digital twin monitoring module, acting as the core brain, sends commands to the adaptive dynamic flow control module and the closed-loop intelligent dust filling module according to the test plan. The adaptive dynamic flow control module maintains constant flow through the critical flow venturi nozzle group, while providing real-time flow data to the closed-loop intelligent dust filling module to accurately calculate and dynamically adjust the dust injection amount. The multi-dimensional intelligent sensing module acts as the sensory nerve of the system, collecting key data such as filter differential pressure, efficiency, and weight in real time and feeding them back to the digital twin. By comparing the real-time data of the physical entity and the virtual model, the digital twin continuously optimizes and issues new control commands, forming a continuous optimization closed loop of perception, decision-making, execution, and verification, thereby achieving accurate, adaptive, and intelligent testing of filter performance throughout its entire life cycle.
7. A dust precision detection device for heavy-duty truck filter production, applicable to the dust precision detection system for heavy-duty truck filter production as described in any one of claims 1-6, characterized in that: The dust detection device for heavy-duty truck filter production includes a bottom cover (1) and a barrel (5). A safety filter element (4) is provided on the inner wall of the barrel (5). A main filter element (3) is slidably connected to the side of the safety filter element (4). An outlet elbow (6) is connected to the side of the barrel (5).
8. The dust detection device for heavy-duty truck filter production according to claim 7, characterized in that: A handle (2) is installed on the side of the barrel (5), and the barrel (5) and the bottom cover (1) are connected by the handle (2).
9. The dust detection device for heavy-duty truck filter production according to claim 7, characterized in that: The side of the outlet bend (6) is connected to a sensor connector (8), the side of the bottom cover (1) is connected to a dust discharge valve (7), and the interior of the outlet bend (6) is connected to the interior of the barrel body (5).