Anti-clogging urea injection system, method and vehicle

Abstract

This invention provides an anti-clogging urea injection system, method, and vehicle, comprising: a mixing assembly having a mixing chamber with an injection port; a liquid supply pump connected to the mixing assembly via a liquid supply pipeline, the mixing chamber being connected to the liquid supply channel of the liquid supply pipeline, the liquid supply pump being used to deliver urea solution to the mixing chamber via the liquid supply pipeline; an air supply assembly connected to the mixing assembly via an air supply pipeline, the mixing chamber being connected to the air supply channel of the air supply pipeline, the air supply assembly being used to deliver compressed air to the mixing chamber via the air supply pipeline, the first end of the air supply pipeline being connected to the mixing assembly via a one-way valve, the one-way valve being used to prevent urea solution in the mixing chamber from flowing back to the air supply assembly; and a pressure sensor located on the air supply pipeline, the pressure sensor being used to acquire the gas pressure in the air supply channel.

Description

Technical Field

[0001] This invention relates to the field of anti-clogging urea injection technology, and more specifically, to an anti-clogging urea injection system, method, and vehicle. Background Technology

[0002] Currently, most existing urea injection systems use one-way valves as isolation elements between the gas and liquid circuits in their mixing components. A liquid pump delivers urea solution to the mixing chamber, while the air supply component introduces compressed air through the air supply line into the mixing chamber for mixing before injection. The pressure sensors typically only monitor the stability of the air supply pressure, lacking intelligent blockage identification and adaptive cleaning functions for the internal flow conditions of the mixing chamber and air supply line. Traditional systems cannot detect abnormal pressure build-up in the air supply line and mixing chamber caused by urea crystal deposition reducing the cross-sectional area of ​​the flow channel. They cannot effectively distinguish between a risky crystallization blockage and normal flow conditions, relying solely on manual periodic disassembly and cleaning or passive backflow prevention via the one-way valve. They cannot automatically trigger cleaning operations based on pressure changes during system operation.

[0003] Under complex operating conditions such as low-temperature crystallization of urea solution, narrowing of nozzle flow channels, and gradual accumulation of deposits downstream of the one-way valve, the mixing chamber and gas supply pipeline are prone to increased flow resistance or even complete blockage. This can lead to either overload damage to the gas supply components due to a continuous abnormal increase in gas supply pressure, or interruption of injection operations and excessive emissions due to undetected blockages. Furthermore, the traditional system's undifferentiated adaptive cleaning control process cannot achieve coordinated operation of quantitative urea solution pre-softening and high-pressure gas-liquid two-phase flushing to address blockage risks. Its poor adaptability makes it difficult to meet the high reliability and stability required for anti-blockage self-cleaning during long-term continuous operation of the urea injection system, resulting in high system blockage failure rates and maintenance costs.

[0004] There is currently no effective solution to the above problems. Summary of the Invention

[0005] The main objective of this invention is to provide an anti-clogging urea injection system, method, and vehicle to solve the technical problem that existing urea injection systems cannot identify the risk of crystallization blockage and the normal flow state of the air supply pipeline and mixing chamber in real time.

[0006] To achieve the above objectives, according to one aspect of the present invention, an anti-clogging urea injection system is provided, comprising: a mixing assembly having a mixing chamber having an injection port; a liquid supply pump connected to the mixing assembly via a liquid supply line, the mixing chamber being connected to a liquid supply channel of the liquid supply line, the liquid supply pump being used to deliver urea solution to the mixing chamber via the liquid supply line; an air supply assembly connected to the mixing assembly via an air supply line, the mixing chamber being connected to an air supply channel of the air supply line, the air supply assembly being used to deliver compressed air to the mixing chamber via the air supply line, a first end of the air supply line being connected to the mixing assembly via a one-way valve, the one-way valve being used to prevent urea solution in the mixing chamber from flowing back to the air supply assembly; and a pressure sensor located on the air supply line, the pressure sensor being used to acquire the gas pressure of the air supply channel.

[0007] Furthermore, the anti-clogging urea injection system also includes: an air valve located on the air supply line, positioned between the pressure sensor and the air supply assembly; and a flow-limiting structure located on the air supply line, positioned between the pressure sensor and the check valve.

[0008] According to another aspect of the present invention, a vehicle is provided, including an anti-clogging urea injection system, the anti-clogging urea injection system comprising the aforementioned anti-clogging urea injection system.

[0009] According to another aspect of the present invention, a method for preventing clogging urea injection is provided. The method is used to control the aforementioned anti-clogging urea injection system, comprising: in response to a system power-on initialization completion signal, acquiring real-time pressure data of the gas supply pipeline detected by a pressure sensor; determining the flow status information of the gas supply pipeline and the mixing chamber based on the real-time pressure data of the gas supply pipeline and a preset pressure threshold, wherein the flow status information includes: a crystallization blockage risk state and a normal flow state; when the flow status information is a crystallization blockage risk state, triggering an automatic pipeline cleaning control process, generating a cleaning control instruction set, the cleaning control instruction set being used to control the liquid supply pump to deliver urea solution into the mixing chamber, control the gas supply component to introduce compressed air into the mixing chamber to form a gas-liquid two-phase mixed flow, and control the gas-liquid two-phase mixed flow to be discharged outward through the injection port.

[0010] Furthermore, based on real-time pressure data and preset pressure thresholds, the flow status information of the gas supply pipeline and mixing chamber is determined, including: comparing the real-time pressure data with the preset pressure thresholds to obtain a comparison result; in response to the comparison result that the real-time pressure data is greater than the preset pressure threshold, the flow status information is determined to be a crystallization blockage risk state; in response to the comparison result that the real-time pressure data is less than or equal to the preset pressure threshold, the flow status information is determined to be a normal flow state.

[0011] Furthermore, the preset pressure thresholds include a first preset pressure threshold and a second preset pressure threshold, wherein the second preset pressure threshold is greater than the first preset pressure threshold. Based on real-time pressure data and the preset pressure thresholds, the flow status information of the gas supply pipeline and mixing chamber is determined, including: comparing the real-time pressure data with the first preset pressure threshold and the second preset pressure threshold respectively; when the real-time pressure data is greater than the first preset pressure threshold and less than or equal to the second preset pressure threshold, the flow status information is determined to be a crystallization blockage risk state; when the real-time pressure data is greater than the second preset pressure threshold, the flow status information is determined to be an overpressure fault state; and in response to the overpressure fault state, a fault alarm command set is generated.

[0012] Furthermore, before determining the flow status information of the gas supply pipeline and mixing chamber based on real-time pressure data and preset pressure thresholds, the process includes: acquiring multiple historical pressure data of the gas supply pipeline within a preset time period; determining pressure change rate data based on multiple historical pressure data; determining the flow status information as a crystallization blockage risk state when the pressure change rate data is greater than the preset change rate threshold; and determining the flow status information as a normal flow state when the pressure change rate data is less than or equal to the preset change rate threshold.

[0013] Furthermore, when the flow status information indicates a risk of crystallization blockage, an automatic pipeline cleaning control process is triggered, generating a cleaning control instruction set, including: generating a liquid supply control instruction set when the flow status information indicates a risk of crystallization blockage, the liquid supply control instruction set is used to control the start of the liquid supply pump to deliver a preset volume of urea solution into the mixing chamber; in response to the completion of the liquid supply control instruction set, generating a set of static delay instructions, the static delay instruction set is used to control the system to maintain a static delay state, the duration of which is a first preset duration; in response to the completion of the static delay instruction set, generating a set of gas supply control instructions, the gas supply control instruction set is used to control the gas supply component to open the air valve, so that compressed air is introduced into the mixing chamber through the gas supply pipeline to form a gas-liquid two-phase mixed flow.

[0014] Furthermore, after controlling the gas-liquid two-phase mixture to flow outward through the injection port, the process also includes: acquiring the pressure data of the gas supply pipeline after cleaning detected by the pressure sensor; determining the cleaning effect information based on the cleaning pressure data and the preset pressure threshold, wherein the cleaning effect information includes: cleaning completed state and cleaning incomplete state; when the cleaning effect information is cleaning completed state, generating a cleaning completed prompt instruction set; when the cleaning effect information is cleaning incomplete state, returning to trigger the automatic pipeline cleaning control process.

[0015] Furthermore, after controlling the gas-liquid two-phase mixed flow to be discharged outward through the injection port, the method further includes: acquiring real-time mixing parameters of the gas-liquid two-phase mixed flow, wherein the mixing parameters include at least: gas-liquid mixing ratio and mixed flow velocity; determining flushing efficiency parameters based on the gas-liquid mixing ratio and mixed flow velocity; and generating a parameter adjustment instruction set when the flushing efficiency parameters are lower than a preset efficiency threshold. The parameter adjustment instruction set is used to adjust the delivery flow rate of the liquid supply pump and / or the gas supply pressure of the gas supply component.

[0016] By applying the technical solution of this invention, a pressure sensor is installed on the gas supply pipeline to obtain the gas pressure of the gas supply channel in real time. The abnormal increase in pressure is used as a quantitative judgment indicator of crystallization blockage. This enables the system to accurately distinguish between the risk state of crystallization blockage and the normal flow state of the pipeline. Based on the state judgment result, the system adaptively triggers the cleaning control process, which completely makes up for the defects of traditional systems such as delayed blockage identification and reliance on manual cleaning. It can avoid damage to the gas supply components due to excessive gas supply pressure and eliminate the problems of injection interruption and excessive emissions caused by unresolved blockage. It is effectively adapted to complex application scenarios such as low temperature crystallization and long-term continuous operation, which greatly improves the intelligence level and operational reliability of the urea injection system in terms of anti-blockage self-cleaning. It significantly reduces the system blockage failure rate and manual maintenance costs, and solves the technical problem that the existing urea injection system cannot identify the risk state of crystallization blockage and the normal flow state of the gas supply pipeline and mixing chamber in real time. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0018] Figure 1 A schematic diagram of the structure of the first embodiment of the anti-clogging urea injection system of the present invention.

[0019] The above figures include the following reference numerals:

[0020] 1. Air valve; 2. Pressure sensor; 3. Flow limiting structure; 4. Mixing assembly; 5. Check valve; 6. Liquid supply pump. Detailed Implementation

[0021] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0022] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0023] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0024] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0025] Currently, the gas-liquid mixing structure design of existing automotive urea injection systems is relatively simple. Most mixing components rely solely on a one-way valve as the core isolation and protection element between the gas and liquid circuits. During normal operation, the system primarily relies on a liquid supply pump to precisely deliver the stored urea solution into the mixing chamber of the mixing component. Simultaneously, compressed air is output from the air supply component and introduced into the mixing chamber via the air supply pipeline, allowing the high-pressure air and urea solution to mix thoroughly within the chamber, ultimately forming an atomized gas-liquid mixture that is ejected from the injection port, thus completing the exhaust gas denitrification and purification process. Conventionally configured pressure sensors only have basic real-time air supply pressure monitoring functions, used only to simply determine the stability of the output air pressure of the air supply component. Their functionality is limited, lacking comprehensive monitoring capabilities of the mixing chamber's internal structure and the entire flow status of the air supply pipeline. They also lack intelligent blockage identification, fault classification, and adaptive cleaning active protection functions.

[0026] Traditional urea injection systems suffer from significant technical limitations in their operation. They cannot capture in real-time changes in flow channels caused by urea solution crystallization and impurity deposition within the air supply pipeline and mixing chamber. Urea solution exhibits a tendency to crystallize at low temperatures. Under conditions such as low-temperature vehicle operation, idling, and frequent switching of operating conditions, urea solution readily crystallizes and accumulates in locations such as the downstream pipeline of the one-way valve, the inner wall of the mixing chamber, and the injection port, continuously reducing the effective cross-sectional area of ​​the flow channel. Traditional systems cannot accurately identify abnormal pressure buildup in the pipelines caused by these conditions, making it difficult to effectively distinguish between normal flow, minor crystallization blockage risk, and severe blockage. Fault identification accuracy is extremely low. The entire system relies solely on the one-way valve for passive urea solution backflow prevention, lacking active detection and intervention mechanisms. Subsequent cleaning of crystallization blockages in the pipelines and chambers depends entirely on manual periodic disassembly, maintenance, and flushing. This maintenance method is outdated and inefficient, failing to automatically determine the blockage risk level and trigger corresponding cleaning operations based on real-time pressure data changes during system operation, resulting in a severe lack of intelligence.

[0027] Under the complex operating conditions of vehicles, multiple factors, such as low temperature, nozzle flow channel narrowing, deposit accumulation downstream of the one-way valve, and residual solution retention in the gas-liquid mixture, can continuously increase the fluid flow resistance in the mixing chamber and air supply pipeline, easily causing malfunctions such as pipeline throttling, cavity stagnation, or even complete blockage. On the one hand, pipeline blockage will prevent the normal release of air pressure in the air supply channel, causing a continuous abnormal increase in air supply pressure. Long-term high-pressure load will directly cause overload, accelerated wear, and shortened lifespan of the air supply components, and in severe cases, it will cause equipment burnout and damage, increasing equipment maintenance costs. On the other hand, when hidden minor blockages are not detected and treated in time, they will gradually develop into severe blockages, directly leading to the interruption of urea injection operations, poor atomization effect, incomplete denitrification of vehicle exhaust, and excessive nitrogen oxide emissions, failing to meet the compliance requirements for vehicle exhaust emissions.

[0028] Meanwhile, traditional urea injection systems lack differentiated and adaptive intelligent cleaning control logic, resulting in a single, fixed cleaning mode. They cannot match corresponding cleaning strategies based on the degree of blockage risk determined by real-time pressure data, and cannot achieve coordinated cleaning operations through quantitative urea solution pre-softening and dissolving combined with high-pressure gas-liquid two-phase powerful flushing. Furthermore, they cannot accurately adapt cleaning intensity and duration to different fault states such as slight crystallization, moderate sludge, and severe blockage, resulting in extremely poor cleaning adaptability and targeting, inconsistent cleaning effects, and an inability to thoroughly remove crystal deposits from pipes and cavities. In summary, traditional urea injection systems are ill-suited to the long-term, continuous, and high-intensity operating conditions of vehicles, and cannot meet the system's requirements for high reliability, high stability, and low failure rate anti-blockage self-cleaning operation. Frequent blockage failures not only significantly increase maintenance costs for equipment inspection and parts replacement but also greatly reduce the operational stability and lifespan of the vehicle's exhaust purification system.

[0029] This application provides an anti-clogging urea injection system, such as... Figure 1 As shown, it includes: a mixing assembly 4, which has a mixing chamber and a spray port; a liquid supply pump 6, which is connected to the mixing assembly 4 via a liquid supply pipeline, and the mixing chamber is connected to the liquid supply channel of the liquid supply pipeline, the liquid supply pump 6 being used to deliver urea solution to the mixing chamber via the liquid supply pipeline; an air supply assembly, which is connected to the mixing assembly 4 via an air supply pipeline, and the mixing chamber is connected to the air supply channel of the air supply pipeline, the air supply assembly being used to deliver compressed air to the mixing chamber via the air supply pipeline, the first end of the air supply pipeline being connected to the mixing assembly 4 via a one-way valve 5, the one-way valve 5 being used to prevent the urea solution in the mixing chamber from flowing back to the air supply assembly; and a pressure sensor 2, which is located on the air supply pipeline, the pressure sensor 2 being used to obtain the gas pressure of the air supply channel.

[0030] This anti-clogging urea injection system has a reasonable structural layout, with all components working in concert. It effectively solves many defects of traditional urea injection systems, such as easy crystallization and clogging, monitoring lag, and poor anti-backflow effect, significantly improving overall operational stability and anti-clogging performance. The system uses a mixing component 4 as the core structure for gas-liquid mixing. It relies on its internal mixing chamber to fully mix the urea solution and compressed air, and then stably completes the atomization injection operation through the injection port, ensuring continuous operation of the exhaust gas denitrification process. The liquid supply pump 6, as the power component for solution delivery, stably delivers the urea solution through the supply pipeline to the mixing chamber inside the mixing component 4, ensuring unobstructed supply channels and a uniform and stable supply volume, providing a reliable medium supply for the system's injection operation. The air supply component, in conjunction with the air supply pipeline, delivers compressed air, which can efficiently mix with the urea solution in the mixing chamber, improving the solution atomization effect and enhancing injection uniformity. A one-way valve 5 is installed between the gas supply pipeline and the mixing component 4 to effectively prevent the urea solution in the mixing chamber from flowing back into the gas supply component. This fundamentally avoids corrosion, liquid accumulation, and crystallization blockage of the gas supply structure caused by urea solution backflow, ensuring a clean and unobstructed gas path system. Pressure sensors 2 are installed on the gas supply pipeline to accurately collect real-time gas pressure data within the gas supply channel. Operators can use this real-time pressure data to determine the flow status within the gas supply pipeline and mixing chamber, quickly identifying abnormal conditions such as crystallization, sludge accumulation, and blockage, enabling early fault prediction. Through the precise coordination of each numbered component, this system constructs a complete anti-backflow, monitorable, and stable injection structure, effectively reducing the probability of pipeline and cavity blockage, minimizing equipment downtime, reducing the frequency of manual maintenance and operating costs, significantly improving the operational reliability and service life of the urea injection system, and adapting to the long-term continuous operation requirements of vehicles.

[0031] Furthermore, the anti-clogging urea injection system also includes: an air valve 1, which is located on the air supply line and is positioned between the pressure sensor 2 and the air supply assembly; and a flow limiting structure 3, which is located on the air supply line and is positioned between the pressure sensor 2 and the check valve 5.

[0032] This embodiment of the anti-clogging urea injection system adds an air valve 1 and a flow-limiting structure 3 to the original structure, optimizing the overall control logic and flow performance of the air supply pipeline. This effectively compensates for the technical defects of traditional urea injection systems, such as poor pressure regulation, unstable airflow, and weak anti-clogging effect, significantly improving system operational stability and anti-clogging capability. The air valve 1 is located between the pressure sensor 2 and the air supply assembly in the air supply pipeline. It can precisely control the on / off state of the air supply pipeline, coordinating with system operating conditions to achieve precise supply and timely cut-off of compressed air. It can promptly block the air path after system shutdown, preventing residual urea mist from backflowing and stagnating in the pipeline, reducing the formation of crystal deposits. Simultaneously, it can work in conjunction with the monitoring data from the pressure sensor 2 to regulate the air supply status, avoiding abnormal operating conditions such as continuous air pressure increase and no-load air supply, protecting the stable operation of the air supply assembly. The flow-limiting structure 3 is positioned between the pressure sensor 2 and the one-way valve 5 in the air supply pipeline. It limits and stabilizes the airflow within the pipeline, effectively balancing the airflow velocity and pressure in the supply channel. This prevents uneven gas-liquid mixing and injection turbulence caused by sudden high-pressure airflow impacts, ensuring that the pressure entering the mixing component 4 remains within a reasonable range. Simultaneously, the flow-limiting structure 3 precisely controls the airflow in the pipeline, assisting the pressure sensor 2 in accurately capturing subtle changes in pipeline pressure, improving the accuracy of blockage fault identification. Combined with the one-way valve 5, it further enhances the system's anti-backflow and anti-crystallization blockage effects. Through the coordinated operation of the air valve 1, the flow-limiting structure 3, the existing pressure sensor 2, one-way valve 5, liquid supply pump 6, and mixing component 4, this system constructs an adjustable, monitorable, and highly stable anti-blockage injection structure. This significantly reduces the probability of pipeline crystallization blockage, decreases equipment failure frequency and manual maintenance costs, effectively improves the continuity and reliability of urea injection operations, and better meets the long-term operational needs of vehicle exhaust purification.

[0033] According to another specific embodiment of this application, a vehicle is also provided, including an anti-clogging urea injection system.

[0034] Applying this technical solution, the vehicle is equipped with a dedicated anti-clogging urea injection system, integrating core components such as air valve 1, pressure sensor 2, flow limiting structure 3, mixing component 4, one-way valve 5, and liquid supply pump 6. This effectively optimizes the vehicle's exhaust gas denitrification and purification performance, solving the drawbacks of traditional vehicle urea injection pipelines, such as easy crystallization and clogging, unstable operation, and high failure rate. The vehicle relies on this injection system to achieve precise mixing and stable injection of urea solution and compressed air. The liquid supply pump 6 stably delivers urea solution, which, together with the compressed air delivered by the air supply component, is fully mixed inside the mixing component 4 and atomized through the injection port, efficiently purifying vehicle exhaust gas and ensuring that vehicle exhaust emissions always meet compliance standards. Through the air valve 1, pressure sensor 2, and flow limiting structure 3 installed on the air supply pipeline, controllable air supply, real-time air pressure monitoring, and airflow stabilization and limiting are achieved, accurately identifying pipeline clogging risks. Combined with the one-way valve 5, it effectively prevents urea solution backflow, significantly reducing pipeline crystallization and equipment overload damage. This system is highly integrated and adaptable, capable of adapting to different vehicle driving conditions and complex low-temperature working environments. It maintains excellent anti-clogging and self-cleaning performance, effectively reducing the maintenance frequency and operating costs of the vehicle's urea injection system, improving the operational stability and service life of the vehicle's exhaust purification system, ensuring long-term, continuous, and reliable vehicle operation, and significantly improving the overall vehicle's environmental performance and operational reliability.

[0035] According to another specific embodiment of this application, an anti-clogging urea injection method is also provided, the method being used to control the above-mentioned anti-clogging urea injection system, comprising:

[0036] Step S10: In response to the system power-on initialization completion signal, acquire the real-time pressure data of the air supply pipeline detected by the pressure sensor;

[0037] In step S10, after the vehicle is powered on and started, the anti-clogging urea injection system first executes its internal power-on initialization program. This program completes self-testing, parameter reset, and communication matching for all electrical components and actuators, including the system controller, pressure sensor 2, air valve 1, liquid supply pump 6, and air supply assembly. Once all system hardware and software self-tests are complete, and stable connections are established between modules without any fault reports, the system generates and outputs a power-on initialization completion signal. This signal serves as the trigger condition for starting the pressure acquisition process, ensuring that subsequent data acquisition operations are conducted under stable system conditions and avoiding data deviations and acquisition failures caused by equipment not being ready.

[0038] Once the power-on initialization completion signal is received by the system's main control unit, the main control unit immediately issues a data acquisition command to activate pressure sensor 2, which is installed on the gas supply pipeline. Pressure sensor 2 then continuously and in real-time collects gas pressure data from inside the gas supply channel of the gas supply pipeline. Pressure sensor 2 is fixedly installed in the pipe section between air valve 1 and flow-limiting structure 3 in the gas supply pipeline. This installation position is downstream of the gas outlet of the gas supply component and upstream of the gas inlet of the mixing component 4. This allows for comprehensive and accurate capture of the actual gas pressure state inside the entire gas supply pipeline, providing complete feedback on pressure parameters under different operating conditions such as pipeline idling, slight congestion, and obstructed flow, thus avoiding sampling errors caused by blind spots in end-point detection.

[0039] During data acquisition, pressure sensor 2 continuously samples according to the system's preset acquisition frequency, acquiring dynamic pressure signals inside the gas supply pipeline in real time. The acquired analog pressure signals are then converted into digital pressure data in real time and simultaneously transmitted to the system's main control unit for storage and preprocessing. This real-time pressure data directly reflects the flow patency of the gas supply pipeline, flow-limiting structure 3, one-way valve 5, and mixing component 4, providing accurate, real-time data support for the subsequent system to determine pipeline flow status, identify crystallization blockage risks, and trigger adaptive cleaning processes. It is the core data basis for achieving intelligent anti-blockage and proactive fault monitoring within the system.

[0040] Step S20: Based on the real-time pressure data of the gas supply pipeline and the preset pressure threshold, determine the flow status information of the gas supply pipeline and the mixing chamber. The flow status information includes: crystallization blockage risk status and normal flow status.

[0041] In step S20, the core step of intelligent judgment of the system's pipeline flow status, it receives the real-time pressure data of the air supply pipeline collected by the aforementioned pressure sensor 2. This data is primarily used to accurately identify the actual flow conditions between the air supply pipeline and the mixing chamber inside the mixing component 4 through data comparison, providing a reliable basis for subsequent anti-blockage and cleaning operations. After the system completes real-time pressure data acquisition and performs data filtering and noise reduction preprocessing, the system's main control unit retrieves the internally stored preset pressure threshold and performs a precise comparison calculation between the acquired real-time pressure data of the air supply pipeline and the preset pressure threshold. The preset pressure threshold is a benchmark parameter pre-calibrated and solidified based on the vehicle's normal operating conditions, the standard air supply pressure of the urea injection system, and pipeline flow resistance parameters. It is adaptable to various normal operating scenarios such as normal temperature, idling speed, and driving load, and can effectively distinguish between normal pipeline flow and abnormal blockage conditions.

[0042] In the specific judgment process, the system uses the relationship between real-time pressure data and preset pressure thresholds as the core judgment criterion to accurately distinguish between two types of pipeline flow status information. When there are trace amounts of urea crystal deposits, scale buildup on the inner wall of the pipeline, slight narrowing of the flow section of the flow-limiting structure 3, or residual impurities accumulating at the front end of the one-way valve 5, the flow resistance inside the gas supply channel and mixing chamber of the gas supply pipeline will increase, resulting in poor gas discharge and consequently, an increase in internal gas pressure. At this time, the real-time pressure data collected by pressure sensor 2 will be higher than the standard operating pressure value. The system can determine the current flow status information as a crystallization blockage risk state by comparing the data, indicating that there is already a slight blockage risk inside the pipeline. If not dealt with in time, it will gradually develop into a severe blockage fault.

[0043] When the air supply pipeline, flow restriction structure 3, one-way valve 5, and mixing component 4 are clean and free of deposits, and the overall airflow is smooth, the compressed air output from the air supply component can enter the mixing chamber normally and quickly without pressure stagnation or accumulation, and the internal pressure of the pipeline is maintained within the standard range. At this time, if the real-time pressure data collected by pressure sensor 2 is less than or equal to the preset pressure threshold, the system can determine that the current flow status is normal, confirming that the current urea injection system's airflow is working well, with no risk of crystallization or blockage. The system can maintain regular injection operations without initiating a cleaning process.

[0044] This threshold comparison method enables automated and precise identification of pipeline flow status, eliminating the reliance on manual observation and reactive fault reporting in traditional systems. It accurately identifies crystallization blockage risks at the nascent stage of blockage, allowing for early detection of potential problems. Furthermore, the judgment logic is simple, efficient, and fast, minimizing system resource consumption. It is adaptable to real-time monitoring needs under dynamic vehicle operating conditions, effectively improving the intelligence and adaptability of urea injection system anti-blockage monitoring.

[0045] Step S30: When the flow status information is in the crystallization blockage risk state, the pipeline automatic cleaning control process is triggered to generate a cleaning control instruction set. The cleaning control instruction set is used to control the liquid supply pump to deliver urea solution into the mixing chamber, control the gas supply component to introduce compressed air into the mixing chamber to form a gas-liquid two-phase mixed flow, and control the gas-liquid two-phase mixed flow to be discharged outward through the injection port.

[0046] In step S30, after the system determines that the gas supply pipeline and the mixing chamber inside the mixing component 4 are in a state of risk of crystallization blockage, the main control unit will immediately switch to execute the preset automatic pipeline cleaning control process, no longer perform the regular urea injection operation, and prioritize the cleaning of pipeline crystal deposits to prevent the continuous accumulation of crystals from causing complete pipeline blockage.

[0047] The main control unit's internal program generates a complete set of cleaning control instructions according to the pre-written control logic. The entire set of instructions includes liquid supply control signals, air supply control signals, and jet conduction control signals output in stages. Each instruction is sent to the corresponding execution component of the system in a sequential order, so as to realize the cleaning process in a step-by-step and orderly manner.

[0048] The cleaning control command set first sends a drive control signal to the liquid supply pump 6 to start its operation. The liquid supply pump 6 uses its power output to transport the stored urea solution along the liquid supply pipeline to the mixing chamber of the mixing component 4. After entering the mixing chamber, the urea solution will wet the inner wall of the chamber, the front end of the one-way valve 5, the inner side of the flow limiting structure 3, and the downstream pipe wall of the gas supply pipeline, where urea crystals are attached. The urea solution softens and hardens the crystals due to its own solubility properties, thus pre-treating them for subsequent airflow to wash away the crystal deposits.

[0049] After the urea solution is delivered, the cleaning control command set synchronously sends a start command to the air supply component. The air supply component outputs compressed air, which flows through the air supply pipeline, through air valve 1, flow limiting structure 3, and one-way valve 5, into the mixing chamber. There, it fully mixes with the urea solution remaining in the chamber, forming a high-pressure gas-liquid two-phase mixed flow. The high-pressure airflow can significantly increase the fluid impact force, overcome the internal flow resistance of the pipeline, and powerfully flush and peel off the softened crystals on the pipe wall and in the chamber.

[0050] The resulting gas-liquid two-phase mixed flow continuously creates a cyclic flushing effect inside the mixing chamber. Under the continuous control of the cleaning control command set, the mixed flow is eventually discharged from the injection port of the mixing component 4. The crystalline impurities that are flushed off will be carried out of the system pipeline and the cavity along with the gas-liquid mixed flow, completing the cleaning operation of the gas supply pipeline and the crystal deposits inside the mixing chamber.

[0051] The entire automatic cleaning process is uniformly coordinated by the cleaning control command set, which coordinates the operation of air valve 1, liquid supply pump 6, and air supply components. No manual intervention is required. The cleaning can be started immediately after identifying potential blockages, avoiding the aggravation of crystal accumulation that could lead to overpressure in the air supply, injection interruption, and excessive exhaust emissions. This effectively improves the smoothness and stability of the long-term operation of the urea injection system.

[0052] Furthermore, based on real-time pressure data and preset pressure thresholds, the flow status information of the gas supply pipeline and mixing chamber is determined, including: comparing the real-time pressure data with the preset pressure thresholds to obtain a comparison result; in response to the comparison result that the real-time pressure data is greater than the preset pressure threshold, the flow status information is determined to be a crystallization blockage risk state; in response to the comparison result that the real-time pressure data is less than or equal to the preset pressure threshold, the flow status information is determined to be a normal flow state. This allows for rapid and accurate determination of whether the gas supply pipeline and mixing chamber are in a crystallization blockage risk state or a normal flow state, achieving real-time identification of pipeline blockage hazards and precise differentiation of operating conditions, effectively improving the accuracy and timeliness of urea injection system operation status monitoring.

[0053] In this embodiment, the preset pressure thresholds include a first preset pressure threshold and a second preset pressure threshold, where the second preset pressure threshold is greater than the first preset pressure threshold. Based on real-time pressure data and the preset pressure thresholds, the flow status information of the gas supply pipeline and mixing chamber is determined, including: comparing the real-time pressure data with the first preset pressure threshold and the second preset pressure threshold respectively; when the real-time pressure data is greater than the first preset pressure threshold and less than or equal to the second preset pressure threshold, the flow status information is determined to be a crystallization blockage risk state; when the real-time pressure data is greater than the second preset pressure threshold, the flow status information is determined to be an overpressure fault state; in response to the overpressure fault state, a fault alarm instruction set is generated, which can distinguish between minor crystallization blockage risk and severe overpressure fault and trigger alarms simultaneously, classifying and identifying pipeline abnormalities, improving monitoring accuracy, and preventing high-pressure damage to components in advance.

[0054] Furthermore, before determining the flow status information of the gas supply pipeline and mixing chamber based on real-time pressure data and preset pressure thresholds, the process also includes: acquiring multiple historical pressure data points of the gas supply pipeline within a preset time period; determining the pressure change rate data based on the multiple historical pressure data points; determining the flow status information as a crystallization blockage risk state when the pressure change rate data is greater than the preset change rate threshold; and determining the flow status information as a normal flow state when the pressure change rate data is less than or equal to the preset change rate threshold. This effectively identifies hidden crystallization blockage risks caused by slow pressure increases, overcomes the limitations of a single static threshold judgment, and significantly improves the comprehensiveness and prediction accuracy of blockage risk identification.

[0055] In this embodiment, when the flow status information indicates a risk of crystallization blockage, an automatic pipeline cleaning control process is triggered, generating a cleaning control command set, including: generating a liquid supply control command set when the flow status information indicates a risk of crystallization blockage, the liquid supply control command set is used to control the liquid supply pump to start, so as to deliver a preset volume of urea solution into the mixing chamber; in response to the completion of the liquid supply control command set, generating a set of static delay command sets, the static delay command set is used to control the system to maintain a static delay state, the duration of the static delay state is a first preset duration; in response to the completion of the static delay command set, generating a set of air supply control command sets, the air supply control command set is used to control the air supply component to open the air valve, so that compressed air is introduced into the mixing chamber through the air supply pipeline to form a gas-liquid two-phase mixed flow, which can effectively soften and remove crystal deposits in the pipeline and mixing chamber, greatly improving the system's self-cleaning effect and anti-blockage reliability.

[0056] Furthermore, after controlling the gas-liquid two-phase mixture to flow outward through the injection port, the process also includes: acquiring the pressure data of the gas supply pipeline after cleaning detected by the pressure sensor; determining the cleaning effect information based on the cleaning pressure data and the preset pressure threshold, wherein the cleaning effect information includes: cleaning completed state and cleaning incomplete state; when the cleaning effect information is cleaning completed state, generating a cleaning completed prompt instruction set; when the cleaning effect information is cleaning incomplete state, returning to trigger the pipeline automatic cleaning control process, forming a closed-loop self-cleaning control, which can completely eliminate crystallization blockage and ensure long-term pipeline unobstructed flow.

[0057] Specifically, the process of controlling the gas-liquid two-phase mixed flow to be discharged outward through the injection port also includes: acquiring real-time mixing parameters of the gas-liquid two-phase mixed flow, wherein the mixing parameters include at least: gas-liquid mixing ratio and mixed flow velocity; determining flushing efficiency parameters based on the gas-liquid mixing ratio and mixed flow velocity; and generating a parameter adjustment instruction set when the flushing efficiency parameters are lower than a preset efficiency threshold. The parameter adjustment instruction set is used to adjust the delivery flow rate of the liquid supply pump and / or the gas supply pressure of the gas supply component to form a closed-loop self-cleaning control, which can completely eliminate crystallization blockage and ensure long-term unobstructed pipeline flow.

[0058] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0059] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this specification.

[0060] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A clog-resistant urea injection system, characterized in that, include: A mixing component (4) having a mixing chamber having an injection port; A liquid supply pump (6) is connected to the mixing assembly (4) through a liquid supply pipeline. The mixing chamber is connected to the liquid supply channel of the liquid supply pipeline. The liquid supply pump (6) is used to transport urea solution to the mixing chamber through the liquid supply pipeline. An air supply assembly is connected to the mixing assembly (4) via an air supply pipeline. The mixing chamber is connected to the air supply channel of the air supply pipeline. The air supply assembly is used to deliver compressed air to the mixing chamber via the air supply pipeline. The first end of the air supply pipeline is connected to the mixing assembly (4) via a one-way valve (5). The one-way valve (5) is used to prevent the urea solution in the mixing chamber from flowing back to the air supply assembly. Pressure sensor (2), the pressure sensor (2) is located on the gas supply pipeline, the pressure sensor (2) is used to obtain the gas pressure of the gas supply channel.

2. The anti-clogging urea injection system according to claim 1, characterized in that, The anti-clogging urea injection system also includes: An air valve (1) is located on the air supply line and is disposed between the pressure sensor (2) and the air supply assembly. A flow limiting structure (3) is located on the gas supply pipeline and is disposed between the pressure sensor (2) and the one-way valve (5).

3. A vehicle comprising an anti-clogging urea injection system, characterized in that, The anti-clogging urea injection system includes the anti-clogging urea injection system as described in claim 1 or 2.

4. A method for preventing clogging urea injection, the method being used to control the anti-clogging urea injection system according to claim 1 or 2, characterized in that, include: In response to the system power-on initialization completion signal, the system acquires real-time pressure data of the air supply pipeline detected by the pressure sensor. Based on the real-time pressure data of the gas supply pipeline and the preset pressure threshold, the flow status information of the gas supply pipeline and the mixing chamber is determined, wherein the flow status information includes: crystallization blockage risk status and normal flow status; When the flow status information is in the crystallization blockage risk state, the pipeline automatic cleaning control process is triggered to generate a cleaning control instruction set. The cleaning control instruction set is used to control the liquid supply pump to deliver urea solution into the mixing chamber, control the gas supply component to introduce compressed air into the mixing chamber to form a gas-liquid two-phase mixed flow, and control the gas-liquid two-phase mixed flow to be discharged outward through the injection port.

5. The anti-clogging urea injection method according to claim 4, characterized in that, Based on the real-time pressure data and the preset pressure threshold, the flow status information of the gas supply pipeline and the mixing chamber is determined, including: The real-time pressure data is compared with the preset pressure threshold to obtain the comparison result; In response to the comparison result that the real-time pressure data is greater than the preset pressure threshold, the flow status information is determined to be the crystallization blockage risk status. In response to the comparison result that the real-time pressure data is less than or equal to the preset pressure threshold, the flow status information is determined to be the normal flow status.

6. The anti-clogging urea injection method according to claim 4, characterized in that, The preset pressure threshold includes a first preset pressure threshold and a second preset pressure threshold, wherein the second preset pressure threshold is greater than the first preset pressure threshold. Based on the real-time pressure data and the preset pressure thresholds, the flow status information of the gas supply pipeline and the mixing chamber is determined, including: The real-time pressure data is compared with the first preset pressure threshold and the second preset pressure threshold, respectively; When the real-time pressure data is greater than the first preset pressure threshold and less than or equal to the second preset pressure threshold, the flow status information is determined to be the crystallization blockage risk status. When the real-time pressure data is greater than the second preset pressure threshold, the flow status information is determined to be an overpressure fault state. In response to the overpressure fault state, a fault alarm instruction set is generated.

7. The anti-clogging urea injection method according to claim 4, characterized in that, Before determining the flow status information of the gas supply pipeline and the mixing chamber based on the real-time pressure data and the preset pressure threshold, the method further includes: Obtain multiple historical pressure data of the gas supply pipeline within a preset time period; Based on the aforementioned historical pressure data, the pressure change rate data is determined; When the pressure change rate data is greater than a preset change rate threshold, the flow status information is determined to be the crystallization blockage risk state; When the pressure change rate data is less than or equal to the preset change rate threshold, the flow status information is determined to be the normal flow status.

8. The anti-clogging urea injection method according to claim 4, characterized in that, When the flow status information indicates a crystallization blockage risk state, the automatic pipeline cleaning control process is triggered, generating a cleaning control instruction set, including: When the flow status information is in the crystallization blockage risk state, a liquid supply control instruction set is generated. The liquid supply control instruction set is used to control the liquid supply pump to start, so as to deliver a preset volume of urea solution into the mixing chamber. In response to the completion of the liquid supply control instruction set, a static delay instruction set is generated. The static delay instruction set is used to control the system to maintain a static delay state. The duration of the static delay state is a first preset duration. In response to the completion of the static delay instruction set, a gas supply control instruction set is generated. The gas supply control instruction set is used to control the gas supply component to open the air valve so that compressed air is introduced into the mixing chamber through the gas supply pipeline to form a gas-liquid two-phase mixed flow.

9. The anti-clogging urea injection method according to claim 4, characterized in that, After the gas-liquid two-phase mixture is controlled to flow outward through the injection port, the method further includes: Obtain the pressure data of the air supply pipeline after cleaning, detected by the pressure sensor; Based on the post-cleaning pressure data and the preset pressure threshold, cleaning effect information is determined, wherein the cleaning effect information includes: cleaning completed status and cleaning incomplete status; When the cleaning effect information indicates that the cleaning is complete, a cleaning completion prompt instruction set is generated; When the cleaning effect information indicates that the cleaning is not completed, the automatic pipeline cleaning control process is triggered.

10. The anti-clogging urea injection method according to claim 8, characterized in that, After the gas-liquid two-phase mixture is controlled to flow outward through the injection port, the method further includes: The real-time mixing parameters of the gas-liquid two-phase mixed flow are obtained, wherein the mixing parameters include at least: gas-liquid mixing ratio and mixed flow velocity; Based on the gas-liquid mixing ratio and the mixed flow velocity, the scouring efficiency parameters are determined; When the flushing efficiency parameter is lower than the preset efficiency threshold, a parameter adjustment instruction set is generated. The parameter adjustment instruction set is used to adjust the delivery flow rate of the liquid supply pump and / or the gas supply pressure of the gas supply component.

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