System and method for diesel oxidation catalyst aging prediction and diagnosis

Abstract

Systems and methods for diagnosing a catalyst of an aftertreatment system are described herein. The system includes an exhaust aftertreatment system and a controller coupled to the exhaust aftertreatment system. The controller receives dosing efficiency data regarding a catalyst of the aftertreatment system and determines an actual aging condition of the catalyst based at least in part on the dosing efficiency data. The controller also receives temperature data indicative of an operating temperature of the catalyst, the temperature data having an associated runtime duration, and determines an expected aging condition of the catalyst based on the temperature data and the associated runtime duration. The controller transmits an early aging notification to a user device in response to the actual aging condition exceeding the expected aging condition.

Description

[0001] This application claims priority under the Paris Convention to Indian patent application filed on 24 February 2025 (application number: 202541015761), the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to the field of exhaust aftertreatment systems, and more specifically to monitoring diesel oxidation catalysts within aftertreatment systems. Background Technology

[0003] An engine can be coupled to an exhaust aftertreatment system to reduce harmful exhaust emissions such as nitrogen oxides (NOx), carbon oxides (such as carbon monoxide (CO) and / or carbon dioxide (CO2)), unburned hydrocarbons, particulate matter, etc. One or more components of the aftertreatment system can operate most efficiently within a predetermined temperature range. For example, when the catalytic converter is within a predetermined temperature range, it can more effectively convert harmful exhaust emissions. However, exhaust temperature can vary with changes in engine and / or system operating conditions. When exhaust temperature changes, the temperature of the aftertreatment system components may also change, thereby affecting the aftertreatment system's ability to operate as intended. Summary of the Invention

[0004] One embodiment relates to a system for diagnosing a catalytic converter in an aftertreatment system. The system includes an exhaust aftertreatment system and a controller coupled to the exhaust aftertreatment system. The controller includes one or more processing circuits, the one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices being configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to perform operations. These operations include receiving a metered feed efficiency for the catalytic converter in the aftertreatment system, and determining actual aging conditions of the catalytic converter based at least in part on the metered feed efficiency. These operations also include receiving temperature data indicating an operating temperature of the catalytic converter, the temperature data having an associated operating time duration; and determining expected aging conditions of the catalytic converter based on the temperature data and the associated operating time duration. These operations also include transmitting an early aging notification to a user equipment in response to actual aging conditions exceeding expected aging conditions.

[0005] Another embodiment relates to a control system for diagnosing a catalyst in a post-treatment system. The control system includes one or more processing circuits, each including one or more memory devices coupled to one or more processors. The memory devices are configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to perform operations. These operations include receiving a metering efficiency for the catalyst in the post-treatment system, and determining actual aging conditions for the catalyst based at least in part on the metering efficiency. These operations also include receiving temperature data indicating an operating temperature of the catalyst, the temperature data having an associated operating time duration; and determining expected aging conditions for the catalyst based on the temperature data and the associated operating time duration. These operations further include transmitting an early aging notification to a user device in response to actual aging conditions exceeding expected aging conditions.

[0006] Another embodiment relates to a method. The method includes: receiving actual aging conditions of a diesel oxidation catalyst based on a metering feed efficiency of the catalyst; receiving expected aging conditions of the catalyst based on temperature data and an operating time duration associated with the temperature data; and transmitting an early aging notification to a user equipment in response to the actual aging conditions exceeding the expected aging conditions.

[0007] This application discloses a system for diagnosing a catalyst in a post-treatment system, the system comprising: An exhaust aftertreatment system; and a controller coupled to the exhaust aftertreatment system, the controller having one or more processing circuits, the one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices being configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors: Receive quantitative feed efficiency information regarding the catalyst of the aftertreatment system; The actual aging conditions of the catalyst are determined at least in part based on the quantitative feed efficiency. Receive temperature data indicating the operating temperature of the catalyst, the temperature data having an associated operating time duration; The expected aging conditions of the catalyst are determined based on the temperature data and the associated operating time duration; and In response to the actual aging conditions exceeding the expected aging conditions, an early aging notification is transmitted to the user equipment.

[0008] In a preferred embodiment, a metering feeder is also included, which is fluidly connected to the aftertreatment system and configured to deliver fuel to the aftertreatment system.

[0009] In a preferred embodiment, the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors, to: Receive data from the metering feeder indicating the amount of fuel supplied to the catalyst by the metering feeder; Receive data from one or more sensors indicating the thermal energy of the exhaust gas supplied to the catalyst; Receive data from the one or more sensors indicating changes in the heat capacity and temperature of the catalyst; and Determine the quantitative feed efficiency of the catalyst.

[0010] In a preferred embodiment, the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors, to: Receive one or more predetermined thresholds from at least one sensor associated with the catalyst; Receive data from the at least one sensor associated with the catalyst; Determine that the data from the at least one sensor satisfies one or more predetermined thresholds; and One or more recommendations for preventative maintenance are generated in response to the data from the at least one sensor not meeting one or more predetermined thresholds.

[0011] In a preferred embodiment, the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors, to: The actual aging conditions of the catalyst are normalized; Normalize the expected aging conditions of the catalyst; and The early aging notification is transmitted to the user equipment in response to the normalized actual aging conditions exceeding the normalized expected aging conditions.

[0012] In a preferred embodiment, the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors, to: Receive one or more predetermined temperature ranges; The temperature data is categorized into corresponding predetermined temperature ranges; Determine the total operating time duration for each of the one or more predetermined temperature ranges; The aging conditions for each of the one or more predetermined temperature ranges are determined based on the corresponding temperature data and the total operating time duration; and The expected aging conditions are determined based on the aging conditions in each of the one or more predetermined temperature ranges.

[0013] In a preferred embodiment, the catalyst is a diesel oxidation catalyst.

[0014] This application also discloses a control system for a catalyst in a diagnostic aftertreatment system, the control system comprising: One or more processing circuits, the one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices being configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors: Receive quantitative feed efficiency information regarding the catalyst of the aftertreatment system; The actual aging conditions of the catalyst are determined at least in part based on the quantitative feed efficiency. Receive temperature data indicating the operating temperature of the catalyst, the temperature data having an associated operating time duration; The expected aging conditions of the catalyst are determined based on the temperature data and the associated operating time duration; and In response to the actual aging conditions exceeding the expected aging conditions, an early aging notification is transmitted to the user equipment.

[0015] In a preferred embodiment, the instructions, when executed by the one or more processors, further cause the one or more processors to: In response to the actual aging conditions exceeding the expected aging conditions, one or more recommendations are generated to address the actual aging conditions; and The one or more suggestions are transmitted to the user equipment.

[0016] In a preferred embodiment, the early aging notification includes at least one of the following: (a) an audible alarm, (b) a graphical user interface displayed by a display device in a system having the catalyst, or (c) a pop-up notification.

[0017] In a preferred embodiment, the instructions, when executed by the one or more processors, further cause the one or more processors to: Receive one or more predetermined thresholds from at least one sensor associated with the catalyst; Receive data from the at least one sensor associated with the catalyst; Determine that the data from the at least one sensor satisfies one or more predetermined thresholds; and One or more recommendations for preventative maintenance are generated in response to sensor data not meeting one or more predetermined thresholds.

[0018] In a preferred embodiment, the instructions, when executed by the one or more processors, further cause the one or more processors to: The actual aging conditions of the catalyst are normalized; Normalize the expected aging conditions of the catalyst; and The early aging notification is transmitted to the user equipment in response to the normalized actual aging conditions exceeding the normalized expected aging conditions.

[0019] In a preferred embodiment, the instructions, when executed by the one or more processors, further cause the one or more processors to: Receive one or more predetermined temperature ranges; The temperature data is categorized into corresponding temperature ranges; Determine the total operating time duration for each of the one or more predetermined temperature ranges; The aging conditions for each of the one or more predetermined temperature ranges are determined based on the corresponding temperature data and the total operating time duration; and The expected aging conditions are determined based on the aging conditions in each of the one or more predetermined temperature ranges.

[0020] In a preferred embodiment, the instructions, when executed by the one or more processors, further cause the one or more processors to: Receive data from the metering feeder indicating the amount of fuel supplied to the catalyst by the metering feeder; Receive data from one or more sensors indicating the thermal energy of the exhaust gas supplied to the catalyst; Receive data indicating changes in the heat capacity and temperature of the catalyst; and Determine the quantitative feed efficiency of the catalyst.

[0021] In a preferred embodiment, the catalyst is a diesel oxidation catalyst.

[0022] This application also discloses a method for diagnosing a catalyst in an aftertreatment system, comprising: The actual aging conditions of the diesel oxidation catalyst are received based on the quantitative feeding efficiency of the diesel oxidation catalyst. The expected aging conditions of the diesel oxidation catalyst are received based on temperature data and the operating time duration associated with the temperature data; and In response to the actual aging conditions exceeding the expected aging conditions, an early aging notification is transmitted to the user equipment.

[0023] In a preferred embodiment, it also includes: Receive data indicating the amount of fuel supplied to the diesel oxidation catalyst by a metering feeder; Receive data indicating the thermal energy of the exhaust gas supplied to the diesel oxidation catalyst; Receive data indicating changes in the heat capacity and temperature of the diesel oxidation catalyst; and Determine the metering efficiency of the diesel oxidation catalyst.

[0024] In a preferred embodiment, it also includes: Receive one or more predetermined thresholds from at least one sensor associated with the diesel oxidation catalyst; Receive data from the at least one sensor associated with the diesel oxidation catalyst; Determine that the data from the at least one sensor satisfies one or more predetermined thresholds; and One or more recommendations for preventative maintenance are generated in response to the data from the sensor not meeting one or more thresholds.

[0025] In a preferred embodiment, it also includes: The actual aging conditions of the diesel oxidation catalyst are normalized; Normalize the expected aging conditions of the diesel oxidation catalyst; and The early aging notification is transmitted to the user equipment in response to the normalized actual aging conditions exceeding the normalized expected aging conditions.

[0026] In a preferred embodiment, it also includes: Receive one or more predetermined temperature ranges; The temperature data is categorized into corresponding predetermined temperature ranges; Determine the total operating time duration for each of the one or more predetermined temperature ranges; The aging conditions for each of the one or more predetermined temperature ranges are determined based on the corresponding temperature data and the total operating time duration; and The expected aging conditions are determined based on the aging conditions in each of the one or more predetermined temperature ranges.

[0027] Numerous specific details are provided to give a thorough understanding of embodiments of the subject matter of this disclosure. The features described in the subject matter of this disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of one aspect of the invention may be combined with one or more features of different aspects of the invention. Furthermore, additional features that may not be present in all embodiments or implementations may be recognized in certain embodiments and / or implementations. Attached Figure Description

[0028] Figure 1 This is a block diagram of an engine system according to an exemplary embodiment.

[0029] Figure 2 According to an exemplary embodiment Figure 1 A block diagram of the system's controller.

[0030] Figure 3 This is a block diagram illustrating a process for determining the metering efficiency of a diesel oxidation catalyst (DOC) according to an exemplary embodiment.

[0031] Figure 4 It is a graphical representation of a process for predicting the actual aging conditions of a DOC according to an exemplary embodiment.

[0032] Figure 5 This is a flowchart of a process for determining estimated aging conditions for DOC according to an exemplary embodiment.

[0033] Figure 6 This is a flowchart of a process for comparing actual diesel oxidation catalyst (DOC) aging time with expected DOC aging time, according to an exemplary embodiment. Detailed Implementation

[0034] The following is a more detailed description of various concepts and embodiments related to methods, apparatuses, and systems for determining the remaining service life of a diesel oxidation catalyst (DOC) within an aftertreatment system. The systems and methods described herein can be applied to a variety of different DOC configurations, such as single-substrate DOCs, dual-substrate DOCs, multifunctional DOCs with integrated particulate filters, etc. Before turning to the accompanying drawings, which illustrate certain exemplary embodiments in detail, it should be understood that this disclosure is not limited to the details or methods set forth in the specification or illustrated in the drawings. It should also be understood that the terminology used herein is for descriptive purposes only and should not be considered limiting.

[0035] As used herein, the term "prediction" and similar terms are used to refer to determining future values ​​based on data (e.g., sensor data, historical sensor data, real-time sensor data, etc.). In some embodiments, one or more models (e.g., statistical models, artificial intelligence models, machine learning models, etc.) may be used to perform predictions of future values. For example, predicting the remaining useful life of a DOC may include using data (such as sensor data and test data) and models to determine the number of operational hours before the DOC fails.

[0036] As used herein, the term "aging conditions" and similar terms refer to the specific temperature at which a diesel oxidation catalyst (DOC) is operated and the duration of the DOC's exposure to that temperature. As described herein, the temperature at which the DOC is operated can be used to calculate a single "aging temperature." For example, this "aging temperature" could be the average operating temperature. The duration of the DOC's exposure to various temperatures can be used to determine a single "aging time." For example, aging time could represent the total operating time of the DOC, or the total operating time of the DOC under predetermined conditions (e.g., when the DOC operates within a specific temperature range). In some instances, temperature data is weighted based on the time the DOC operates at a given temperature, such that operating temperatures with longer durations are weighted more heavily than those with shorter durations.

[0037] The performance of a diesel oxidation catalyst (DOC) can deteriorate over time due to conditions it has been exposed to, such as catalyst poisoning, hydrothermal aging, and catalyst surface clogging. Catalyst poisoning refers to the reduced efficiency of the DOC due to the accumulation of substances (e.g., sulfur, lead, ash, etc.) within the DOC that inhibit its ability to promote chemical reactions. Hydrothermal aging refers to the deterioration of DOC performance due to prolonged exposure to the high temperatures and water vapor present in diesel engine exhaust. Catalyst surface clogging refers to the blockage or sealing of the DOC's inlet or outlet surfaces (e.g., "faces"). This blockage can prevent or restrict exhaust flow through the DOC (e.g., the catalyst cannot perform its intended function, such as oxidizing hydrocarbons, carbon monoxide, etc., in the exhaust).

[0038] Based on the foregoing and with general reference to the accompanying drawings, the various embodiments disclosed herein relate to systems, apparatus, and methods for determining and comparing expected aging conditions of a diesel oxidation catalyst (DOC) with actual aging conditions of the DOC. These systems may include systems for vehicles. These systems may include one or more sensors coupled to an aftertreatment system and a controller having one or more processing circuitry, the one or more processing circuitry including one or more memory devices coupled to one or more processors. The controller may receive a metering efficiency of the diesel oxidation catalyst and determine the actual aging conditions of the diesel oxidation catalyst based on the metering efficiency. The controller may also receive temperature data indicating the operating temperature of the diesel oxidation catalyst, the temperature data having an associated operating time duration, and determine the expected aging conditions of the diesel oxidation catalyst based on the temperature data and the associated operating time duration. The controller transmits an early aging notification to the user equipment in response to actual aging conditions exceeding expected aging conditions.

[0039] The systems, computer-readable media, and methods described herein provide a technical solution to the challenge of determining the remaining service life of diesel oxidation catalysts (DOCs) using real-time and test data. These methods enable controllers to assess whether DOC aging is occurring faster than expected and to notify relevant users (e.g., drivers, service engineers, DOC manufacturers) of the DOC's aging conditions. If DOC aging is occurring faster than expected, the controller can generate recommendations. These recommendations can include guidance for drivers to change their driving behaviors, which can help mitigate or eliminate factors that accelerate DOC aging, such as high operating temperatures, inefficient metering, catalyst poisoning, hydrothermal aging, and catalyst surface clogging. Additionally, these notifications and recommendations can help service engineers diagnose DOC problems or predict their failure, thereby improving maintenance and operational efficiency. Furthermore, the controller's ability to provide DOC life predictions can reduce unexpected downtime and maintenance costs. First, an indication that DOC aging is occurring faster than expected allows for proactive maintenance scheduling. By predicting when the DOC is likely to fail, maintenance can be planned at a convenient time, avoiding unexpected failures. Second, early detection of accelerated DOC aging helps prevent secondary damage to other vehicle components. When DOC does not function optimally, it can lead to increased emissions and potential damage to the engine and exhaust system. These and other features and benefits will be described below.

[0040] Now for reference Figure 1 The diagram illustrates a block diagram of a system 100 according to an example embodiment. The system 100 includes an engine 101 and an aftertreatment system 120 in exhaust receiving communication with the engine 101. The system 100 may also include a controller 140 and operator input / output (I / O) devices (in... Figure 2(As shown in the diagram), where the controller 140 is communicatively coupled to each of the aforementioned components. Figure 1 In this configuration, the system 100 is included in a vehicle. The vehicle can be any type of on-road or off-road vehicle, including but not limited to wheel loaders, forklifts, long-haul trucks, medium-duty trucks (e.g., pickup trucks), cars, coupes, tanks, aircraft, boats, and any other type of vehicle. In another embodiment, the system 100 may be embodied in a fixed piece of equipment, such as a generator or generator set. All such variations are intended to fall within the scope of this disclosure.

[0041] Engine 101 can be any type of internal combustion engine that produces exhaust gas, such as a gasoline engine, a natural gas engine, or a diesel engine, and / or any other suitable engine. In the depicted example, engine 101 is part of a diesel engine system. In other embodiments, engine 101 is part of a hybrid power system having a combination of an internal combustion engine and at least one electric motor coupled to at least one battery. In some embodiments, the hybrid power system can be configured as a mild hybrid system, a parallel hybrid system, a series hybrid system, or a series-parallel power system.

[0042] like Figure 1 As shown, an intake throttle (IAT) valve 102, a fuel module 103, an oil system 104, and an aftertreatment system 120 are coupled to an engine 101. The IAT valve 102 is configured to control the amount of air supplied to the engine 101. The fuel module 103 is configured to supply fuel to the engine 101 (e.g., from a fuel source). The fuel module 103 can control one or more fuel supply parameters, including fuel quantity, fuel pressure, fuel injection timing, etc. The fuel module 103 can further control post-injection of fuel into the combustion chamber of the engine 101. The post-injection process causes a portion of the fuel (e.g., diesel or hydrocarbon) to be carried into the exhaust gas as it leaves the engine 101. The oil system 104 is configured to supply lubricant (e.g., lubricating oil) to the engine 101.

[0043] IAT valve 102 is a valve located at the air inlet of engine 101. IAT valve 102 can be actuated between an open position and a closed position (e.g., by an actuator controlled by controller 140). In the open position, IAT valve 102 allows the maximum amount of air to flow from the air inlet to engine 101. In the closed position, IAT valve 102 allows the minimum amount of air to flow from the air inlet to engine 101. Controller 140 can selectively actuate IAT valve 102 between and / or in multiple positions including both open and closed positions (e.g., by controlling an actuator) to adjust the amount of air received by engine 101.

[0044] The aftertreatment system 120 forms an exhaust receiving communication with the engine 101. In the depicted example, the aftertreatment system includes: a first catalyst component shown as a diesel oxidation catalyst (DOC) 121, a filter (e.g., a particulate filter) shown as a diesel particulate filter (DPF) 122, and a second catalyst component shown as a selective catalytic reduction (SCR) 123 system. In some embodiments, the aftertreatment system 120 includes a third catalyst component shown as an ammonia slip catalyst (ASC) 128. DOC 121, DPF 122, and SCR 123 can be fluidly connected via an exhaust duct. DOC 121 is configured to receive exhaust gas from the engine 110 and oxidize one or more exhaust components (e.g., hydrocarbons, carbon monoxide, etc.) in the exhaust gas. DPF 122 is arranged or positioned downstream of DOC 121 and is configured to remove particulate matter or particulate matter (such as soot) from the exhaust gas flowing in the exhaust stream. DPF 122 includes an inlet and an outlet, where exhaust gas is received at the inlet and exits at the outlet after particulate matter has been substantially filtered out of the exhaust gas. In some embodiments, DPF 122 or other components may be omitted and / or other components may be added (e.g., a second SCR system with additional metering units or modules, multiple DOCs, etc.). Additionally, although in Figure 1 The diagram shows a specific arrangement of the post-processing system 120, but in other embodiments the arrangement of components within the post-processing system 120 may be different (e.g., DPF 122 is located downstream of SCR 123 and ASC).

[0045] The aftertreatment system is shown to include a hydrocarbon mixer 127 (e.g., a hydrocarbon decomposition chamber, a hydrocarbon mixing chamber mixer, etc.). The hydrocarbon decomposition chamber is located upstream of DOC 121. The hydrocarbon mixer 127 is configured to receive exhaust gas from exhaust duct 108. A hydrocarbon metering module 126 (e.g., a metering unit, metering feeder, metering device, etc.) is coupled to the hydrocarbon mixer 127 and configured to deliver fuel (such as hydrocarbons) to the aftertreatment system 120. The hydrocarbon metering module 126 is configured to facilitate hydrocarbon fluid entry into the hydrocarbon mixer 127. The hydrocarbon metering module 126 may include at least one hydrocarbon injector (e.g., an insertion device, etc.). The hydrocarbon injector is configured to meterly feed hydrocarbon fluid (e.g., from a fuel / hydrocarbon source) into the exhaust gas within the hydrocarbon mixer 127.

[0046] The hydrocarbons within the hydrocarbon mixer 127 can be configured to increase the temperature of the exhaust gas within the hydrocarbon mixer 127. In some instances, the aftertreatment system 120 includes an igniter (e.g., a spark plug, etc.) coupled to the hydrocarbon mixer 127. This igniter is configured to burn the hydrocarbon fluid in the exhaust gas within the hydrocarbon mixer 127, thereby increasing the exhaust gas temperature. Therefore, regeneration of downstream components may occur. For example, regeneration occurs when the hydrocarbon fluid in the exhaust gas burns and increases the exhaust gas temperature so that any soot or particles that may have adhered to downstream components are burned off. By burning off the adhered soot or particles, downstream components can be thoroughly cleaned, leaving them virtually new and operational.

[0047] The aftertreatment system 120 may also include a reductant delivery system, which may include a decomposition chamber (e.g., a decomposition reactor, reactor conduit, decomposition pipe, reactor tube, etc.) to convert the reductant into ammonia, as shown in the metering module 124. The reductant may be, for example, urea, diesel exhaust fluid (DEF), Adblue®, urea aqueous solution (UWS), urea aqueous solution (e.g., AUS32, etc.), and other similar fluids. The metering module 124 may include a storage chamber, a pump, and a nozzle (and possibly other components or equipment). The storage chamber may be configured to store the reductant. The pump may be fluidly connected to the storage chamber and the nozzle via a metering conduit and is configured to pump the reductant from the storage chamber to the nozzle. The nozzle may supply the reductant to the exhaust gas within the exhaust conduit. Adding the reductant fluid to the exhaust gas stream aids in catalytic reduction. Figure 1 As shown, the reducing agent can typically be injected upstream of the SCR 123 (or specifically the SCR catalyst) via a metering module 124, causing the SCR catalyst to receive the mixture of the reducing agent and exhaust gas. The reducing agent droplets then undergo evaporation, thermal decomposition, and hydrolysis processes to form gaseous ammonia within the decomposition chamber, the SCR catalyst, and / or the exhaust duct system, which exits the aftertreatment system 120.

[0048] DOC 121 is fluidly coupled to an exhaust duct system to oxidize one or more gaseous components of the exhaust gas (e.g., hydrocarbons, carbon oxides, etc.). To effectively assist in the oxidation of these gaseous components, DOC 121 may need to be at an operating temperature. In some embodiments, this operating temperature is between approximately 200°C and 500°C. In other embodiments, this operating temperature is the temperature at which the conversion efficiency of DOC 121 exceeds a predefined threshold (e.g., the conversion of hydrocarbons into less harmful compounds, referred to as hydrocarbon conversion efficiency).

[0049] SCR 123 is configured to assist in the reduction of NOx emissions by accelerating the NOx reduction process between ammonia and exhaust NOx to diatomic nitrogen (N2) and water (H2O). If the SCR catalyst is not at or above a certain temperature, the acceleration of the NOx reduction process is limited, and the SCR 123 may not operate at the desired conversion efficiency (i.e., a value indicating the amount of NOx emissions reduced, also known as "NOx removal efficiency") level. In some embodiments, this certain temperature is approximately 200°C to 600°C. The SCR catalyst can be made from a combination of inactive materials and an active catalyst, such that the inactive material (e.g., a ceramic substrate) directs the exhaust gas to the active catalyst, which is any kind of material suitable for catalytic reduction (e.g., metal-exchanged zeolite (Fe or Cu / zeolite), base metal oxides (such as vanadium, molybdenum, tungsten, etc.)).

[0050] When ammonia in the exhaust gas does not react with the SCR catalyst (either because SCR 123 is below operating temperature, or because the amount of ammonia fed in a metered manner greatly exceeds the amount of NOR), unreacted ammonia may bind to the SCR catalyst and be stored in SCR 123. When SCR 123 is heated, this stored ammonia is released from SCR 123. If the amount of ammonia released is greater than the amount of NOx passing through (i.e., more ammonia than the amount of NOx required), it can cause problems, leading to ammonia slip. In some embodiments, an ASC 128 is included and configured to address ammonia slip by removing at least some of the excess ammonia from the treated exhaust gas before it is released into the atmosphere. As the exhaust gas passes through ASC 128, some of the unreacted ammonia remaining in the exhaust gas (i.e., ammonia that has not reacted with NOx) is partially oxidized to NOx, which then reacts with the remaining unreacted ammonia to form N2 gas and water. However, similar to SCR catalysts, the acceleration of the NH3 reduction process is limited if the ASC 128 is not at or above a certain temperature, and the ASC 128 may not operate at an efficiency level that meets regulations or required parameters. In some embodiments, this certain temperature is approximately 250°C to 300°C.

[0051] As shown in the figure, multiple sensors 125 are included in the aftertreatment system 120. The number, placement, and type of sensors included in the aftertreatment system 120 are shown for illustrative purposes only. That is, in other configurations, the number, placement, and type of sensors may be different. Sensors 125 may be gas composition sensors (e.g., NOx sensors, oxygen sensors, etc.), temperature sensors, particulate matter (PM) sensors, flow sensors (e.g., mass flow sensors, volumetric flow sensors, etc.), other exhaust emission component sensors, pressure sensors, and some combinations thereof. Gas composition sensors may include oxygen sensors configured to acquire data indicating the presence of oxygen in the exhaust gas. Data from the oxygen sensor can be used to estimate the AFR value. Flow sensors may include mass air flow (MAF) sensors configured to acquire data indicating the mass flow rate of the exhaust gas. Temperature sensors are configured to acquire data indicating the temperature value at each location where a temperature sensor is located.

[0052] Sensor 125 may be located in or near engine 101, after engine 101 and before aftertreatment system 120, after aftertreatment system 120, in the aftertreatment system as shown (e.g., coupled to DPF and / or DOC, coupled to SCR, etc.), upstream of engine 101, etc. It should be understood that the sensor location can vary. In one embodiment, sensors 125 may be present both before and after aftertreatment system 120. In one embodiment, at least one of these sensors is configured as an exhaust component sensor (e.g., CO, NOx, PM, SOx, etc. sensor). In another embodiment, at least one of the sensors 125 is configured as a non-exhaust component sensor for estimating exhaust emissions (e.g., temperature, flow rate, pressure, etc.). System 100 may also include additional sensors. These sensors may include engine-related sensors (e.g., torque sensor, speed sensor, pressure sensor, flow sensor, temperature sensor, etc.). For example, in some embodiments, at least one of the sensors 125 is configured as an oil temperature sensor for detecting and / or determining engine oil temperature. These sensors may also include sensors associated with other components of the vehicle (e.g., turbocharger speed sensors, fuel quantity and injection rate sensors, fuel rail pressure sensors, etc.).

[0053] Sensor 125 can be real or virtual (i.e., a non-physical sensor configured as part of the program logic for various estimations or determinations in controller 140). For example, an engine speed sensor can be a real or virtual sensor used to measure or otherwise acquire data, values, or information indicating the speed of engine 101 (typically expressed in revolutions per minute). The sensor is coupled to the engine (when configured as a real sensor) and configured to send a signal indicating the speed of engine 101 to controller 140. When configured as a virtual sensor, controller 140 can use at least one input in algorithms, models, lookup tables, etc., to determine or estimate engine parameters (e.g., power output, etc.). Any of the sensors 125 described herein can be real or virtual.

[0054] Controller 140 is coupled to sensor 125, and particularly communicatively coupled to sensor 125. Therefore, controller 140 is configured to receive data from one or more sensors 125 and to provide instructions / information to those sensors. Controller 140 can use the received data to control one or more components in system 100 and / or for monitoring and thermal management purposes.

[0055] Operator Input / Output (I / O) Device 130 (in Figure 2 (As shown in the diagram) can be coupled to controller 140, enabling information exchange between controller 140 and I / O device 130, wherein this information can be... Figure 1 This relates to the determination (described below) of one or more components or controllers 140. Operator I / O device 130 enables the operator of system 100 to communicate with... Figure 1 The system 100's controller 140 communicates with one or more components. For example, operator input / output devices may include, but are not limited to, interactive displays, touchscreen devices, one or more buttons and switches, voice command receivers, etc. Thus, operator input / output device 130 can provide the operator with one or more instructions or notifications, such as a fault indicator light (MIL). Additionally, the vehicle may include a port that allows the controller 140 to connect to or couple to a scanning tool, enabling the acquisition of fault codes and other information about the vehicle.

[0056] In some embodiments, operator I / O device 130 includes an operator interface device. In some embodiments, the operator interface device is a button or switch, such as a momentary switch. In other embodiments, the operator interface device is a graphical user interface provided on the display of operator I / O device 130 or part of such a graphical user interface. For example, the operator interface device may be an interactive icon or similar element of a graphical user interface that can be selected by a user via touch input or using another device such as a keyboard or mouse. In some embodiments, operator I / O device 130 includes processing circuitry that enables communication (e.g., wired and wireless connections) between the operator interface device and controller 140.

[0057] Controller 140 is configured to at least partially control system 100 and associated subsystems (such as engine 101 and operator I / O devices 130). Communication between components can be achieved via any number of wired or wireless connections. For example, wired connections may include serial cables, fiber optic cables, CAT5 cables, or any other form of wired connection. In contrast, wireless connections may include the Internet, Wi-Fi, cellular networks, radio, etc. In one embodiment, a controller local area network (CAN) bus provides the exchange of signals, information, and / or data. The CAN bus includes any number of wired and wireless connections. Because controller 140 is communicatively coupled to... Figure 1 The system and components, so the controller 140 is configured to receive from Figure 1 Data for one or more of the components shown. The structure and function of controller 140 will be discussed regarding... Figure 2 Further description.

[0058] because Figure 1 The components are shown as being embodied in the vehicle, so the controller 140 can be configured as one or more electronic control units (ECUs), such as one or more microcontrollers. The controller 140 can be separate from or included in at least one of the transmission control unit, exhaust aftertreatment control unit, powertrain control module, engine control module, etc.

[0059] Now for reference Figure 2 This illustrates an example embodiment. Figure 1 A schematic diagram of the controller 140 of the system 100. As shown, the controller 140 includes at least one processing circuit 202 having at least one processor 204 and at least one memory device 206, a DOC prediction circuit 212, and a communication interface 216.

[0060] In one configuration, the DOC prediction circuit 212 is embodied as a machine- or computer-readable medium storing instructions to be executed by a processor (such as processor 204). As described herein and among other uses, the machine-readable medium facilitates the execution of certain operations to achieve the reception and transmission of data. For example, the machine-readable medium can provide instructions (e.g., commands, etc.) to, for example, acquire data. In this respect, the machine-readable medium may include programmable logic defining the frequency of data acquisition (or data transmission). The computer-readable medium instructions may include code that can be written in any programming language, including but not limited to Java, and any conventional procedural programming language such as "C" or similar programming languages. The computer-readable program code can be executed on one processor or multiple remote processors. In the latter case, the remote processors can be connected to each other via any type of network (e.g., CAN bus, etc.).

[0061] In another configuration, the DOC prediction circuit 212 is embodied as one or more hardware units, such as one or more electronic control units. Therefore, the DOC prediction circuit 212 can be embodied as one or more circuit components, including (but not limited to) processing circuitry, network interfaces, peripherals, input devices, output devices, sensors, etc. In some embodiments, the DOC prediction circuit 212 can take the form of one or more analog circuits, electronic circuits (e.g., integrated circuits (ICs), discrete circuits, system-on-a-chip (SOC) circuits, microcontrollers, etc.), telecommunications circuits, hybrid circuits, and any other type of "circuit". At this point, the DOC prediction circuit 212 can include any type of component for implementing or facilitating the implementation of the operations described herein. For example, the circuitry described herein can include one or more transistors, logic gates (e.g., NAND, AND, NOR, OR, XOR, NOT, XNOR, etc.), resistors, multiplexers, registers, capacitors, inductors, diodes, wiring, etc. The DOC prediction circuit 212 can also include or be a programmable hardware device, such as a field-programmable gate array, programmable array logic, programmable logic device, etc. DOC prediction circuit 212 may include one or more memory devices for storing instructions executed by the processor of DOC prediction circuit 212. The one or more memory devices and the processor may have the same definitions provided below with respect to memory device 206 and processor 204. In some hardware unit configurations, DOC prediction circuit 212 may be geographically distributed in various individual locations within the vehicle. Alternatively, and as shown, DOC prediction circuit 212 may be embodied in or within a single unit / housing, which is shown as controller 140.

[0062] In the illustrated example, controller 140 includes processing circuitry 202 having a processor 204 and a memory device 206. This processing circuitry 202 may be constructed or configured to execute or implement the instructions, commands, and / or control processes described herein with respect to DOC prediction circuitry 212. The depicted configuration indicates that DOC prediction circuitry 212 is embodied as a machine or computer-readable medium storing instructions. However, as mentioned above, this description is not intended to be limiting, as this disclosure contemplates other embodiments in which DOC prediction circuitry 212 is configured as a hardware unit. All such combinations and variations are intended to fall within the scope of this disclosure.

[0063] Processor 204 may be implemented as one or more single-chip or multi-chip processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), and / or suitable processors (e.g., other programmable logic devices, discrete hardware components, etc., to perform the functions described herein). The processor may be a microprocessor, a set of processors, etc. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a combination of multiple microprocessors, a combination of one or more microprocessors incorporating a DSP core, or any other such configuration. In some embodiments, the one or more processors may be shared by multiple circuits (e.g., DOC prediction circuitry 212 may include or otherwise share the same processor, which in some example embodiments may execute instructions stored or otherwise accessed via different regions of memory). Alternatively or additionally, the one or more processors may be configured to perform or otherwise perform certain operations independently of one or more coprocessors. In other example embodiments, two or more processors may be bus-coupled to enable independent, parallel, pipelined, or multithreaded instruction execution. All such variations are intended to fall within the scope of this disclosure.

[0064] Memory device 206 (e.g., memory, memory cell, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage device) for storing data and / or computer code to perform or facilitate the various processes, layers, and modules described herein. For example, memory device 206 may include dynamic random access memory (DRAM). Memory device 206 may be communicatively connected to processor 204 to provide processor 204 with computer code or instructions for performing at least some of the processes described herein. Furthermore, memory device 206 may be or include tangible, non-transient volatile memory or non-volatile memory. Therefore, memory device 206 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described herein.

[0065] Communication interface 216 may include any combination of wired and / or wireless interfaces (e.g., jacks, antennas, transmitters, receivers, transceivers, terminal blocks) for data communication with various systems, devices, or networks configured to enable in-vehicle communication (e.g., between components of the vehicle) and / or external communication (e.g., with a remote server). For example, regarding external / system communication, communication interface 216 may include an Ethernet card and ports for sending and receiving data via an Ethernet-based communication network and / or a Wi-Fi transceiver for communication via a wireless communication network. Communication interface 216 may be configured to communicate via a local area network or a wide area network (e.g., the Internet) and may use various communication protocols (e.g., IP, LON, Bluetooth, ZigBee, radio, cellular, near-field communication).

[0066] like Figure 2 As shown, the communication interface 216 enables communication with the engine 101, the aftertreatment system 120 (and / or its catalytic devices, such as DOC 121), and the sensor 125.

[0067] DOC prediction circuit 212 is configured or constructed to determine or calculate the actual aging conditions and the expected aging conditions of DOC 121. DOC prediction circuit 212 compares the actual aging conditions of DOC 121 with the expected aging conditions to draw one or more conclusions about the health status of DOC 121. For example, if the actual aging conditions exceed the expected aging conditions, DOC prediction circuit 212 can diagnose that DOC 121 has excessive actual aging conditions, such as catalyst misalignment, upstream hardware failure of DOC 121, or smoke from engine 101 (e.g., smoke output from engine 101 causing soot deposits that block or obscure the inlet of DOC 121).

[0068] The expected aging condition refers to at least one reference aging condition value determined based on temperature data associated with DOC 121 (e.g., collected by sensor 125). This calculation or determination can be performed by controller 200. More specifically, DOC prediction circuit 212 can determine the expected aging condition, which will be discussed below. Figure 5 To provide a more detailed description.

[0069] The actual aging conditions of DOC 121 are calculated or determined by the controller, or more specifically, by the DOC prediction circuit 212 based on the metering efficiency of DOC 121. The “metering efficiency” of DOC 121 refers to the effectiveness of converting metered fuel (e.g., fuel injected by hydrocarbon metering module 126) into useful heat (e.g., heat generated by the injected fuel or hydrocarbons, which raises the exhaust temperature as it passes through DOC 121). This process can be performed by the controller 200, or more specifically, by the DOC prediction circuit 212, to determine the actual aging conditions of DOC 121, which will be discussed below. Figure 3 and Figure 4 To provide a more detailed description.

[0070] Now for reference Figure 3 This diagram illustrates a block diagram of a process 300 for determining the metering efficiency of DOC 121 according to an exemplary embodiment. In the exemplary embodiment, controller 200, and more specifically, DOC prediction circuit 212, executes process 300. In other instances, a remote computing system (e.g., a provider computing system, or some other computing system remotely located relative to system 100) determines the metering efficiency of DOC 121 and transmits that metering efficiency to DOC prediction circuit 212. Thus, DOC prediction circuit 212 can receive and / or determine the metering efficiency of DOC 121.

[0071] like Figure 3 As shown, the calorific value (Q) of the hydrocarbons injected into the exhaust stream HC定量给料 ) and the amount of exhaust gas with specific thermal energy (Q) 排气 ) is the input for DOC 121. Q HC定量给料 This indicates the thermal energy available from the hydrocarbons injected into the fuel stream (e.g., for use by DOC 121). 排气 This represents the thermal energy in the exhaust gas before metered feeding (e.g., via fuel injection) and before oxidation in DOC 121. Additionally, DOC 121 can store or gain heat (Q) over time due to changes in its internal temperature (e.g., due to changes in the temperature of the exhaust gas received by DOC 121). DOC热增量 Q DOC热增量 This represents the input to the DOC prediction circuit 212 when determining the quantitative feeding efficiency.

[0072] Q HC定量给料 Q 排气 Q DOC热增量 Determined by the following formula: Regarding Q HC定量给料 HC 定量给料 This indicates the amount (e.g., mass) of hydrocarbons (e.g., diesel fuel) injected into the exhaust stream and supplied to the DOC 121 (e.g., via hydrocarbon metering module 126, via post-injection from fuel module 103). Such data can be collected by hydrocarbon metering module 126 and / or fuel module 103 and transmitted to DOC prediction circuit 212. LHV 燃料 This indicates the predetermined lower heating value (LHV) of a specific type of fuel injected into the exhaust stream.

[0073] Regarding Q 排气 m Exh This value represents the mass of the exhaust gas flowing through DOC 121. In some instances, the mass of the exhaust gas is a predetermined value. Additionally or alternatively, the DOC prediction circuit 212 can determine the mass of the exhaust gas based on data indicating the mass of the exhaust gas from one or more of the sensors 125 (e.g., a mass flow sensor, etc.). p This is the predetermined specific heat capacity of the exhaust gas. dT represents the temperature difference between the exhaust gas at the inlet of DOC 121 and DOC 121. Such temperature data can be collected by sensors 125 (and in particular thermistors) located upstream and downstream of DOC 121 and transmitted to DOC prediction circuit 212. In such an example, dT represents the difference between the upstream temperature measurement and the downstream temperature measurement.

[0074] Regarding Q DOC热增量 The heat capacity represents the heat capacity of DOC 121, which may depend on the mass and / or material properties of DOC 121. The heat capacity quantifies how much heat DOC 121 can store per degree of temperature change. dT / dt represents the rate of temperature change within the DOC. Specifically, dT represents the temperature change within the DOC, which can be measured by sensor 125, while dt represents the change in time (e.g., the time elapsed since the start of temperature measurement).

[0075] Use Q HC定量给料 The DOC prediction circuit 212 determines Q using the following formula. 预期 : Q 预期 It represents an estimate of the heat expected to be generated in DOC 121 by the injected hydrocarbon fuel (e.g., from hydrocarbon metering module 126, or from post-injection from fuel module 103). 热This represents a predetermined thermal efficiency coefficient, which indicates the efficiency with which a quantitatively fed hydrocarbon is converted into heat. As mentioned above, Q HC定量给料 This indicates the calorific value of the hydrocarbons injected into the exhaust stream.

[0076] The DOC prediction circuit 212 can then use Q 预期 Q 排气 Q DOC热增量 To calculate the quantitative feeding efficiency (μ) 定量给料 ).

[0077] The quantitative feed efficiency algorithm will use the actual thermal energy rate (e.g., Q) 排气 Q DOC热增量 ) and the expected thermal energy rate from hydrocarbon injection (e.g., Q) 预期 The results were compared to determine the effectiveness of the aftertreatment system in hydrocarbon injection and conversion during regeneration events.

[0078] refer to Figure 4 The diagram illustrates a graphical representation of a process 400 for predicting the actual RUL of DOC 121 according to an exemplary embodiment. In the exemplary embodiment, controller 200, and more specifically, DOC prediction circuit 212, executes process 400. In other instances, a remote computing system (e.g., a provider computing system, or some other computing system remotely located relative to system 100) predicts the actual RUL of DOC 121 and transmits the predicted actual RUL to DOC prediction circuit 212. Thus, DOC 121 can receive and / or predict the actual RUL.

[0079] Process 400 is shown as involving the metering efficiency (μ) of DOC 121. 定量给料 The aging temperature (shown as y-axis 402) is plotted against the aging temperature (shown as x-axis 404). In some instances, process 400 includes plotting one or more test data points 406 on a graph of metering efficiency versus aging temperature. Each test data point 406 represents a DOC aged for a fixed amount of time (e.g., in a laboratory) at a specific temperature. This determines the aging temperature (e.g., x-axis) of the test data point. The aging temperature represents the specified temperature the DOC is subjected to and the duration the DOC is held at that specified temperature.

[0080] The metering efficiency of the tested DOC can then be calculated using the above-described process 300. This testing process can be repeated on multiple DOCs until a trend line 408 can be plotted between test data points 406 (e.g., using a regression algorithm). This trend line 408 is used to determine the equation 410 (e.g., a polynomial equation) representing the test data. As shown in equation 410, the aging temperature x is the independent variable, and the metering efficiency y is the dependent variable. Since the metering efficiency can be calculated by the DOC prediction circuit 212 using various measurement data, the dependent variable can be solved by the DOC prediction circuit 212 using process 300. Thus, the DOC prediction circuit 212 can then use the metering efficiency to determine or calculate the independent variable—the aging temperature. Then, as indicated by point 412, a curve of metering efficiency and aging temperature can be plotted to determine the actual aging temperature of the DOC 121. The DOC prediction circuit 212 can then use algorithms, models, lookup tables, etc., to estimate the duration (e.g., xx℃ for yy hours) that the DOC 121 will maintain at the actual aging temperature.

[0081] Technically and practically, the test data and the associated trend line 408 can be used to estimate the failure temperature 414. This failure temperature 414 refers to the temperature threshold at which the DOC reaches failure or undergoes irreversible degradation. For example, this might be the temperature at which the DOC becomes inefficient or fails to function as intended. For instance, oxidation of a specific chemical contaminant may fall below a predefined desired threshold. As another example, the mass flow rate through the DOC may fall below a predefined desired threshold, which indicates severe blockage on the DOC surface. As an example, since the test data point 406 indicating DOC failure (e.g., the test data point 406 falling within the lower shaded portion of the graph) falls within the range of the tested temperatures, the DOC prediction circuit 212 can determine the failure aging temperature 414 by locating the corresponding point on the trend line (e.g., at the intersection between the lower shaded portion and the unshaded portion of the graph). This failure temperature 414 can be used to estimate the total service life of the DOC 121. For example, after determining the failure temperature of 414, a DOC similar to DOC 121 (e.g., similar size and / or model) can be run until failure occurs at the failure temperature of 414. This duration can be used for comparison to determine the remaining service life of the DOC121, as will be considered regarding... Figure 6 To describe in more detail.

[0082] refer to Figure 5A flowchart illustrating a process for determining estimated aging conditions for DOC 121 according to an exemplary embodiment is shown. As a summary, DOC prediction circuit 212 may collect operating temperature data of DOC 121 and time data of DOC 121 operating at each of a plurality of temperatures (which may also be one of a plurality of temperature ranges). DOC prediction circuit 212 may categorize the temperature data and associated operating time into predetermined temperature ranges. DOC prediction circuit 212 may then determine a metric for the temperature within each range and determine the total amount of time operated within each temperature range. In the example shown, this metric is the average temperature. However, in other embodiments, different metrics may be utilized. The average temperature and total operating time for each range may then be normalized (e.g., by an algorithm, model, lookup table, etc.) to determine the equivalent time of operation at the failure temperature (e.g., failure temperature 414 determined in process 400). The equivalent operating time may then be averaged to determine the expected aging conditions for DOC 121.

[0083] like Figure 5 As shown, DOC prediction circuit 212 is illustrated to receive a predetermined set of operating temperature ranges associated with DOC 121, which are shown as a first range 502, a second range 504, a third range 506, and a fourth range 508. Such ranges may be transmitted to DOC prediction circuit 212, for example, by a DOC provider, manufacturer, and / or fleet manager. Sensor 125 (and particularly a temperature sensor or thermistor) transmits data indicating the operating temperature of DOC 121 to DOC prediction circuit 212 (e.g., continuously, almost continuously, in predetermined transmission increments, etc.). This temperature data is categorized by DOC prediction circuit 212 into corresponding temperature ranges (e.g., first range 502, second range 504, third range 506, fourth range 508, etc.). In some instances, the temperature data includes the corresponding amount of time that DOC 121 takes to operate at a given temperature. In other instances, one or more timers may measure the corresponding amount of time that DOC 121 takes to operate at a given temperature. The DOC prediction circuit 212 can then average the operating temperature over each range and determine the total amount of time the DOC 121 operates within each range. An example of this process is shown in the table below: Once the DOC prediction circuit 212 has the average temperature (temperature metric) and total runtime for each of the first range 502, second range 504, third range 506, and fourth range 508, the DOC prediction circuit 212 can normalize the temperature and total runtime for each range (e.g., by applying an algorithm, model, or formula (such as an Arrhenius-based formula) to each dataset), making them directly comparable. In an exemplary embodiment, the DOC prediction circuit 212 normalizes the temperature and total runtime for each range using a thermal aging equation (e.g., a hydrothermal operating condition equation). As an example, to normalize the four sets of input data (e.g., the temperature and total runtime for each of the first range 502, second range 504, third range 506, and fourth range 508), the hydrothermal operating condition equation processes these data to calculate the equivalent runtime at a specified failure temperature, which accounts for the relationship between temperature and aging rate.

[0084] The output of the normalization process is four equivalent operating times 512, 514, 516, and 518 at the selected failure temperature (e.g., aging yy hours at the failure temperature °C). These times indicate how long DOC 121 will need to operate at the failure temperature to experience the same degree of aging as it would under the actual conditions defined by each input. The normalized output allows DOC prediction circuit 212 to directly compare the severity of aging on different input data from the first range 502, the second range 504, the third range 506, and the fourth range 508, regardless of the varying operating temperature and duration. Thus, at process 520, DOC prediction circuit 212 can determine or calculate the expected aging time of DOC 121 based on the normalized aging temperature data (e.g., using algorithms, models, lookup tables, etc.). As an example, the expected aging conditions of DOC 121 can be determined or calculated by averaging the four equivalent operating times at the selected failure temperature.

[0085] Now for reference Figure 6 This illustrates a process 600, according to an exemplary embodiment, for comparing the actual aging time of DOC 121 with the expected aging time of DOC 121. This process 600 may be executed by controller 200, or more specifically, by DOC prediction circuitry 212. In some embodiments, a remote computing system executes all or part of process 600. It should be understood that the processes of 600 may be executed in a different order, some processes may be omitted, and / or some processes may be added, still falling within the spirit and scope of this disclosure.

[0086] At step 602, the DOC prediction circuit 212 and / or the remote computing system perform the above process 400 to determine the aging temperature based on the metering efficiency. (As mentioned above regarding...) Figure 3 and Figure 4 The DOC prediction circuit 212 and / or the remote computing system discussed herein use an equation relating metering efficiency to aging temperature to determine (a) the metering efficiency of DOC 121 and (b) the aging temperature. As an example, the DOC prediction circuit 212 and / or the remote computing system can determine that DOC 121 is aged at 1000°C for 15 hours (i.e., the actual aging conditions).

[0087] At step 604, the DOC prediction circuit 212 and / or the remote computing system normalize the aging temperature output from process 400 (e.g., by applying an algorithm, model, or formula). As an example, to normalize the aging temperature output from process 400, the hydrothermal real-world aging equation processes this data to calculate the equivalent run time at a specified failure temperature, which explains the relationship between temperature and aging rate. The hydrothermal real-world aging equation for a diesel oxidation catalyst mathematically converts the time spent at different temperatures into an equivalent aging time at a reference failure temperature. This hydrothermal real-world aging equation applies an Arrhenius-based transformation, where higher temperatures disproportionately affect aging due to their exponential effect on reaction rates. By integrating the time spent at each temperature with a scaling factor based on activation energy and the gas constant (R = 8.314 J / (mol·K)), the hydrothermal real-world aging equation converts varying temperature exposures into a single normalized aging duration. The output of the normalization process is the equivalent run time at the selected failure temperature (e.g., failure temperature 414). Continuing with the above example, the DOC prediction circuit 212 and / or the remote computing system can determine that aging for 15 hours at 1000°C is equivalent to aging for 8 hours at a failure temperature of 1170°C.

[0088] At step 608, the DOC prediction circuit 212 and / or the remote computing system perform the above-described process 500 to determine the expected aging time of DOC 121. (As mentioned above...) Figure 5 The DOC prediction circuit 212 and / or the remote computing system calculate the expected aging time of DOC 121 based on normalized aging temperature data (e.g., using algorithms, models, lookup tables, etc.). Continuing with the above example, the output of process 500 can be the expected aging conditions, which are normalized to aging for 5 hours at a failure temperature of 1170°C.

[0089] Since both the expected and actual aging times are normalized to the equivalent operating time at the specified failure temperature, the expected and actual aging times of DOC 121 can be directly compared by the DOC prediction circuit 212 at step 610. According to the example above, the actual aging time is normalized to 8 hours at a failure temperature of 1170°C, while the expected aging time is normalized to 5 hours at the failure temperature of 1170°C. Because the actual aging time (8 hours) at the failure temperature is greater than the expected aging time (5 hours) at the failure temperature, DOC 121 is aging faster than expected. This can indicate that DOC 121 is experiencing a problem or is in danger.

[0090] Additionally or alternatively, the DOC prediction circuit 212 can determine the remaining useful life (RUL) of DOC 121. As described above, one or more DOCs similar to DOC 121 (e.g., similar size, model, construction, etc.) can be tested to determine how long a particular DOC can operate at the failure temperature before failing or undergoing irreversible degradation. This duration can be used for comparison to determine the remaining useful life of DOC 121. Continuing with the above example, test data can reveal that multiple tested DOCs 121 can operate for 15 hours at a failure temperature of 1170°C. The DOC prediction circuit 212 can then determine the difference between the useful life at the failure temperature and the following two: (a) the actual aging conditions and (b) the expected aging conditions. Continuing with the above example, the actual RUL at a failure temperature of 1170°C is 7 hours (from 15 hours to 8 hours), and the expected RUL at a failure temperature of 1170°C is 10 hours (from 15 hours to 5 hours). Since the actual RUL is less than the expected RUL of DOC 121, DOC 121 ages faster than expected. As mentioned above, this can indicate that there is a problem or danger with DOC 121.

[0091] If the actual aging time exceeds the expected aging time at the failure temperature, the DOC prediction circuit 212 proceeds to step 612 of process 600. At step 612, the DOC prediction circuit generates an early aging notification. This early aging notification (and any other notifications described herein) can be constructed in various formats, such as a push notification sent to a remote device (e.g., a user's mobile device), a notification provided within a mobile application executed / running on a user device (e.g., a smartphone) communicatively coupled to the DOC prediction circuit 212, a notification (e.g., a pop-up message) on the operator I / O device (e.g., a dashboard display device) of the vehicle / system containing the DOC, a message displayed on a computer display connected to the DOC prediction circuit 212 (separate from the system / vehicle containing the DOC 121), and / or some other form of notification method. In some embodiments, the DOC prediction circuit 212 generates a recommendation (614) for addressing early aging. For example, faster-than-expected aging of DOC 121 could be due to catalytic converter positioning, upstream hardware failure of DOC 121, and / or smoke from engine 101 (e.g., smoke from engine 101 causing soot deposits that block or obscure the DOC 121 inlet). This notification may include an indication of the problem, and at least one recommendation. This at least one recommendation may include a suggestion for a service provider to inspect catalytic converter positioning, upstream hardware failure of DOC 121, and / or smoke from engine 101. In some embodiments, DOC prediction circuitry 212 may identify a anticipated cause of premature aging of DOC 121 and may generate a recommendation based on the identified cause. For example, sensor 125 (and particularly the oxygen sensor) may detect that the oxygen in the exhaust outlet of engine 101 is below a predetermined threshold, indicating that engine 101 is smoking (e.g., due to improper combustion, etc.). DOC prediction circuitry 212 may receive an indication or determination that the oxygen in the exhaust has dropped below the predetermined threshold and may further generate a recommendation instructing a service provider to inspect engine 101.

[0092] At step 616, the DOC prediction circuit 212 transmits an early aging notification and / or suggestion to a user device (such as I / O device 130). As described above, the early aging notification and the suggestion to address early aging can be included in a graphical user interface (GUI) configured to be displayed on I / O device 130. For example, the GUI may include a written warning stating: “The diesel oxidation catalyst in vehicle A is aging faster than expected. Consider having a mechanic perform a fuel test to check for catalyst poisoning.” The early aging notification, including at least one suggestion, can be displayed on I / O device 130, for example, as a pop-up notification, in an application stored on I / O device 130, as a message such as a text message or email message, or some combination thereof. Users (e.g., provider employees, customers, etc.) can log in to the application or a web-based interface to view the suggestion. In some embodiments, logging in may include receiving at least one authentication credential (e.g., device token, username and password, PIN, a combination thereof, etc.). Authenticating I / O device 130 and / or the user enables the remote computing system to access and receive early aging notifications, expected aging times, actual aging times, and / or recommendations regarding aging times. In the absence of authenticated I / O device 130, early aging notifications can be securely stored and inaccessible. As mentioned above, the authentication credentials can be a universal password, code, token, and / or other types of credentials. In some instances, early aging notifications are audible or audiovisual alarms output on I / O device 130. For example, an early aging notification could be an audible message stating: "Warning: Early aging of DOC detected. Please contact the maintenance provider as soon as possible."

[0093] If the actual aging time is less than or equal to the expected aging time, the DOC prediction circuit 212 proceeds to step 618 of process 600. At step 618, the DOC prediction circuit 212 may receive and evaluate the cumulative operating time of system 100. In some instances, the DOC prediction circuit 212 compares the cumulative operating time of system 100 to one or more preset threshold operating times. These preset threshold operating times may be based on test data to indicate at what operating time system 100 (and particularly DOC 121) should be serviced to maintain emission levels within a specific range (e.g., according to local regulations, etc.).

[0094] At step 620, the DOC prediction circuit 212 may receive or (in some embodiments) determine a fault condition (e.g., indicating a problem within the SCR, DOC, DPF, DEF metering system, etc.) regarding system 100 (and more specifically, the aftertreatment system 120). Therefore, the DOC prediction circuit 212 may receive or determine indicators (e.g., on-board diagnostic codes, such as OBD codes, diagnostic fault codes, fault codes, etc.) regarding the operation of engine 101 and / or aftertreatment system 120. The DOC prediction circuit 212 may use these indicators to determine a potential state / condition regarding these components (e.g., health status, whether a component is operating as expected, etc.). These indicators may be used to determine whether / how to perform maintenance on system 100. For example, sensor 125 may detect one or more conditions of system 100. For example, sensor 125 may include particulate matter (PM) sensors that detect the concentration of soot and other fine particles in the exhaust stream. The DOC prediction circuit 212 may receive a predetermined threshold associated with a “normal” or “acceptable” concentration of particles in the exhaust stream. DOC prediction circuit 212 can compare data received from the PM sensor with a predetermined normal / acceptable value or range of values, and determine whether particulate matter meets a predetermined threshold (e.g., particulate matter exceeding the highest value of a predetermined acceptable range, or particulate matter falling below the lowest value of that predetermined acceptable range). As another example, at least one of the sensors 125 can be configured as an exhaust component sensor (e.g., CO, NOx, PM, SOx, etc.). DOC prediction circuit 212 can receive a predetermined threshold or range of values ​​associated with a "normal" or "acceptable" amount of a specific type of gas in the exhaust. For example, the predetermined threshold can be set based on acceptable NOx values ​​published by a regulatory agency. DOC prediction circuit 212 can compare data received from the exhaust sensors with a predetermined normal / acceptable value or range of values, and determine whether the exhaust components meet the predetermined threshold. If the measured NOx concentration falls within an acceptable range, the system operates as intended. However, if these levels exceed the threshold, it can indicate a malfunction within SCR 123 or diesel oxidation catalyst (DOC) 120. In such cases, the DOC prediction circuit 212 can determine that the exhaust composition does not meet a predetermined threshold, thereby triggering a diagnostic warning or fault code. This diagnostic warning or fault code can be displayed on a user device such as I / O device 130. For example, and as described above with respect to step 616, the diagnostic warning and / or fault code can be included in a graphical user interface (GUI) configured to be displayed on I / O device 130. For example, the GUI might include a written warning stating: “The NOx concentration of vehicle A is approaching the NOx limit set by the regulatory authority; consider having a service technician check the aftertreatment system.”

[0095] At step 622, the DOC prediction circuit 212 may transmit the RUL (Rating Limit of the DOC 121) to user equipment (such as I / O device 130). The RUL indicates approximately how long the DOC can operate at its failure temperature before failing or undergoing irreversible degradation. The RUL can be used to plan maintenance and / or repair of the DOC. For example, if the RUL meets a predetermined threshold, the DOC prediction circuit 212 may transmit a notification to the user or repair provider indicating that the DOC requires repair and / or preventative maintenance. Additionally or alternatively, the DOC 121 may transmit a notification to the driver regarding adjustments to driving behavior. For example, if the load on the vehicle exceeds a predetermined threshold, the DOC 121 may transmit a notification to the driver stating, "Frequent heavy-load driving increases engine workload, leading to increased stress on the DOC; please consider carrying a load of less than X weight for the next trip." Technically and practically, such notifications to drivers can reduce or slow premature aging of the DOC by prompting them to change their driving behavior.

[0096] As used herein, the terms “about,” “approximately,” “substantially,” and similar terms are intended to have a broad meaning consistent with common and accepted usage by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art who read this disclosure will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or irrelevant modifications or alterations to the described and claimed subject matter are considered to fall within the scope of this disclosure as set forth in the appended claims.

[0097] It should be noted that the term “exemplary” and its variations, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible instances, representations or illustrations of possible embodiments (and such terms are not intended to imply that such embodiments are necessarily extraordinary or best instances).

[0098] As used herein, the term “coupled” and its variations mean that two components are directly or indirectly connected to each other. This connection can be stationary (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such a connection can be achieved when two components are directly coupled to each other, when two components are coupled to each other using one or more separate intermediate components, or when two components are coupled to each other using an intermediate component that is integrally formed with one of the two components to form a single whole. If “coupled” or its variations are modified by an additional term (e.g., direct coupling), the general definition of “coupled” provided above is modified by the common linguistic meaning of the additional term (e.g., “direct coupling” means that two components are connected without any separate intermediate component), making the definition narrower than the general definition of “coupled” provided above. This coupling can be mechanical, electrical, or fluid. For example, circuit A being “coupled” to circuit B can mean that circuit A communicates directly with circuit B (i.e., without intermediaries) or indirectly with circuit B (e.g., through one or more intermediaries).

[0099] Although Figure 2 The diagram illustrates a circuit with a specific function; however, it should be understood that the controller 200 may include any number of circuits for performing the functions described herein. For example, the activity and function of the DOC prediction circuit 212 may be distributed across multiple circuits or as a single circuit as shown. Additional circuits with additional functions may also be included. Furthermore, the controller 200 may further control other activities beyond the scope of this disclosure.

[0100] As described above and in one configuration, the "circuit" can be implemented in a machine-readable medium storing instructions for execution by various types of processors, such as processor 204. For example, the identified executable code circuit may include one or more physical or logical blocks of computer instructions, which may be organized, for example, as objects, procedures, or functions. However, the executable code of the identified circuit does not need to be physically placed together, but may include different instructions stored in different locations that, when logically connected, constitute the circuit and achieve its intended purpose. In practice, the circuit of computer-readable program code can be a single instruction or multiple instructions, and can even be distributed across several different code segments, different programs, and several memory devices. Similarly, operational data can be identified and illustrated within the circuit herein, and can be embodied in any suitable form and organized within any suitable type of data structure. This operational data can be collected as a single dataset, or it can be distributed across different locations (including across different storage devices), and can exist at least partially as electronic signals on a system or network.

[0101] While the term "processor" has been briefly defined above, the terms "processor" and "processing circuitry" should be interpreted broadly. In this respect, and as stated above, a "processor" can be implemented as one or more processors, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), or other suitable electronic data processing components configured to execute instructions provided by memory. The one or more processors can take the form of a single-core processor, a multi-core processor (e.g., a dual-core processor, a triple-core processor, a quad-core processor, etc.), a microprocessor, etc. In some embodiments, the one or more processors can be located externally to the device; for example, the one or more processors can be remote processors (e.g., cloud-based processors). Alternatively or additionally, the one or more processors can be internal and / or local to the device. In this respect, a given circuitry or its components can be located locally (e.g., in a local computing system, etc.) or remotely (e.g., as part of a remote server such as a cloud-based server). Therefore, a "circuitry" as described herein can include components distributed across one or more locations.

[0102] Although the accompanying drawings and descriptions may illustrate a specific order of method steps, such order may differ from the order depicted and described unless otherwise stated above. Similarly, unless otherwise stated above, two or more steps may be performed simultaneously or partially simultaneously. Such variations may depend on, for example, the chosen software and hardware system and the designer's choices. All such variations are within the scope of this disclosure.

[0103] The foregoing description of embodiments has been presented for purposes of illustration and description. This foregoing description is not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and modifications and variations may be made in accordance with the foregoing teachings, or may be obtained from the present disclosure. The embodiments were chosen and described to explain the principles of the present disclosure and its practical application, enabling those skilled in the art to utilize various embodiments and to have various modifications suitable for the particular purpose contemplated. Other substitutions, modifications, alterations, and omissions may be made in the design, operating conditions, and arrangement of the embodiments without departing from the scope of the present disclosure as set forth in the appended claims.

[0104] Therefore, this disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects merely illustrative and not restrictive. Therefore, the scope of this disclosure is indicated by the appended claims rather than by the foregoing description. All variations within the meaning and scope of equivalents of the claims are included within the scope of the claims.

Claims

1. A system for diagnosing a catalyst in an aftertreatment system, the system comprising: Exhaust aftertreatment system; and a controller coupled to the exhaust aftertreatment system, the controller having one or more processing circuits, the one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices being configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors: Receive quantitative feed efficiency information regarding the catalyst of the aftertreatment system; The actual aging conditions of the catalyst are determined at least in part based on the quantitative feed efficiency. Receive temperature data indicating the operating temperature of the catalyst, the temperature data having an associated operating time duration; The expected aging conditions of the catalyst are determined based on the temperature data and the associated operating time duration. as well as In response to the actual aging conditions exceeding the expected aging conditions, an early aging notification is transmitted to the user equipment.

2. The system of claim 1 further includes a metering feeder fluidly connected to the aftertreatment system and configured to deliver fuel to the aftertreatment system.

3. The system of claim 2, wherein the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors: Receive data from the metering feeder indicating the amount of fuel supplied to the catalyst by the metering feeder; Receive data from one or more sensors indicating the thermal energy of the exhaust gas supplied to the catalyst; Receive data from the one or more sensors indicating changes in the heat capacity and temperature of the catalyst; as well as Determine the quantitative feed efficiency of the catalyst.

4. The system of claim 1, wherein the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors, to: Receive one or more predetermined thresholds from at least one sensor associated with the catalyst; Receive data from the at least one sensor associated with the catalyst; Determine that the data from the at least one sensor satisfies one or more predetermined thresholds; as well as One or more recommendations for preventative maintenance are generated in response to the data from the at least one sensor not meeting one or more predetermined thresholds.

5. The system according to any one of claims 1-4, wherein the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors, to: The actual aging conditions of the catalyst are normalized; Normalize the expected aging conditions of the catalyst; and The early aging notification is transmitted to the user equipment in response to the normalized actual aging conditions exceeding the normalized expected aging conditions.

6. The system according to any one of claims 1-4, wherein the one or more memory devices are further configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors: Receive one or more predetermined temperature ranges; The temperature data is categorized into corresponding predetermined temperature ranges; Determine the total operating time duration for each of the one or more predetermined temperature ranges; The aging conditions for each of the one or more predetermined temperature ranges are determined based on the corresponding temperature data and the total operating time duration. as well as The expected aging conditions are determined based on the aging conditions in each of the one or more predetermined temperature ranges.

7. The system according to any one of claims 1-4, wherein the catalyst is a diesel oxidation catalyst.

8. A control system for a catalytic converter in a diagnostic aftertreatment system, the control system comprising: One or more processing circuits, the one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices being configured to store instructions on the one or more memory devices, the instructions causing the one or more processors, when executed by the one or more processors: Receive quantitative feed efficiency information regarding the catalyst of the aftertreatment system; The actual aging conditions of the catalyst are determined at least in part based on the quantitative feed efficiency. Receive temperature data indicating the operating temperature of the catalyst, the temperature data having an associated operating time duration; The expected aging conditions of the catalyst are determined based on the temperature data and the associated operating time duration. as well as In response to the actual aging conditions exceeding the expected aging conditions, an early aging notification is transmitted to the user equipment.

9. The control system of claim 8, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to: In response to the actual aging conditions exceeding the expected aging conditions, one or more recommendations are generated to address the actual aging conditions; and The one or more suggestions are transmitted to the user equipment.

10. The control system of claim 8, wherein the early aging notification comprises at least one of: (a) an audible alarm, (b) a graphical user interface displayed by a display device in a system having the catalyst, or (c) a pop-up notification.

11. The control system of claim 8, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to: Receive one or more predetermined thresholds from at least one sensor associated with the catalyst; Receive data from the at least one sensor associated with the catalyst; Determine that the data from the at least one sensor satisfies one or more predetermined thresholds; as well as One or more recommendations for preventative maintenance are generated in response to sensor data not meeting one or more predetermined thresholds.

12. The control system according to any one of claims 8-11, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to: The actual aging conditions of the catalyst are normalized; Normalize the expected aging conditions of the catalyst; and The early aging notification is transmitted to the user equipment in response to the normalized actual aging conditions exceeding the normalized expected aging conditions.

13. The control system according to any one of claims 8-11, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to: Receive one or more predetermined temperature ranges; The temperature data is categorized into corresponding temperature ranges; Determine the total operating time duration for each of the one or more predetermined temperature ranges; The aging conditions for each of the one or more predetermined temperature ranges are determined based on the corresponding temperature data and the total operating time duration. as well as The expected aging conditions are determined based on the aging conditions in each of the one or more predetermined temperature ranges.

14. The control system according to any one of claims 8-11, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to: Receive data from the metering feeder indicating the amount of fuel supplied to the catalyst by the metering feeder; Receive data from one or more sensors indicating the thermal energy of the exhaust gas supplied to the catalyst; Receive data indicating the heat capacity and temperature changes of the catalyst; as well as Determine the quantitative feed efficiency of the catalyst.

15. The control system according to any one of claims 14-11, wherein the catalyst is a diesel oxidation catalyst.

16. A method for diagnosing a catalyst in an aftertreatment system, comprising: The actual aging conditions of the diesel oxidation catalyst are received based on the quantitative feeding efficiency of the diesel oxidation catalyst. The expected aging conditions of the diesel oxidation catalyst are received based on temperature data and the operating time duration associated with the temperature data. as well as In response to the actual aging conditions exceeding the expected aging conditions, an early aging notification is transmitted to the user equipment.

17. The method of claim 16, further comprising: Receive data indicating the amount of fuel supplied to the diesel oxidation catalyst by a metering feeder; Receive data indicating the thermal energy of the exhaust gas supplied to the diesel oxidation catalyst; Receive data indicating the heat capacity and temperature changes of the diesel oxidation catalyst; as well as Determine the metering efficiency of the diesel oxidation catalyst.

18. The method of claim 16, further comprising: Receive one or more predetermined thresholds from at least one sensor associated with the diesel oxidation catalyst; Receive data from the at least one sensor associated with the diesel oxidation catalyst; Determine that the data from the at least one sensor satisfies one or more predetermined thresholds; as well as One or more recommendations for preventative maintenance are generated in response to the data from the sensor not meeting one or more thresholds.

19. The method according to any one of claims 16-18, further comprising: The actual aging conditions of the diesel oxidation catalyst are normalized; The expected aging conditions of the diesel oxidation catalyst are normalized; as well as The early aging notification is transmitted to the user equipment in response to the normalized actual aging conditions exceeding the normalized expected aging conditions.

20. The method according to any one of claims 16-18, further comprising: Receive one or more predetermined temperature ranges; The temperature data is categorized into corresponding predetermined temperature ranges; Determine the total operating time duration for each of the one or more predetermined temperature ranges; The aging conditions for each of the one or more predetermined temperature ranges are determined based on the corresponding temperature data and the total operating time duration. as well as The expected aging conditions are determined based on the aging conditions in each of the one or more predetermined temperature ranges.

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