Heating system for diesel exhaust fluid tank

Abstract

To provide an improved DEF heating system.SOLUTION: A system and apparatus include a diesel exhaust fluid tank, a first temperature sensor that is positioned within the diesel exhaust fluid tank and is structured to provide first temperature information indicative of a first temperature, and a second temperature sensor that is positioned within the diesel exhaust fluid tank and is structured to provide second temperature information indicative of a second temperature. The system and apparatus further include one or more processing circuits that include one or more memory devices coupled to one or more processors. The one or more memory devices are configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to provide energy to a heating system on the basis of the first temperature information and the second temperature information.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 104,848, filed on October 23, 2020, the entire content of which is incorporated herein by reference.

[0002] Technical Field The present disclosure relates to an engine exhaust after - treatment system. More particularly, the present disclosure relates to systems and methods for diesel exhaust fluid (DEF) management in a selective catalytic reduction (SCR) after - treatment system.

Background Art

[0003] Background SCR after - treatment systems consume diesel exhaust fluid (DEF). DEF typically contains 32.5% urea and 67.5% de - ionized water. Typically, DEF freezes at minus 12 degrees Celsius (-12°C) or 11 degrees Fahrenheit (11°F).

Summary of the Invention

[0004] Summary One aspect is a diesel exhaust fluid tank, a first temperature sensor positioned within the diesel exhaust fluid tank and configured to provide first temperature information indicative of a first temperature, a second temperature sensor positioned within the diesel exhaust fluid tank and configured to provide second temperature information indicative of a second temperature, one or more processing circuits including one or more memory devices coupled to one or more processors, wherein the one or more memory devices store instructions that, when executed by the one or more processors, cause the one or more processors to provide energy to a heating system based on the first temperature information and the second temperature information One or more processing circuits configured to store Relates to a diesel exhaust fluid system including

[0005] Another aspect relates to a diesel exhaust fluid tank control system for use with a diesel exhaust fluid tank including a temperature and ultrasonic level and concentration (TULC) sensor and a heating system. The diesel exhaust fluid tank control system A temperature sensor array positioned within the diesel exhaust fluid tank and constructed to provide temperature information, One or more processing circuits including one or more memory devices coupled to one or more processors, wherein the one or more memory devices Instructions that, when executed by the one or more processors, cause the one or more processors to provide energy to the heating system based on the temperature information One or more processing circuits configured to store Including

[0006] Another aspect relates to a method including receiving primary temperature information indicative of a primary temperature from a first temperature sensor positioned within a diesel exhaust fluid tank, receiving secondary temperature information indicative of a secondary temperature from a temperature sensor array positioned within the diesel exhaust fluid tank, and selectively providing energy to a heating system positioned within the diesel exhaust fluid tank based on the primary temperature and the secondary temperature.

[0007] This summary is merely exemplary and is in no way intended to be limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, when considered in conjunction with the accompanying figures, in which like reference numerals refer to like elements. BRIEF DESCRIPTION OF THE DRAWINGS

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

DETAILED DESCRIPTION

[0009] DETAILED DESCRIPTION Various concepts related to methods, apparatuses, and systems for thawing a diesel exhaust fluid (DEF) tank, and more detailed descriptions of embodiments of those methods, apparatuses, and systems follow. Before referring to the figures that illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methods described in this description or illustrated in the figures. Also, it should be understood that the terms used herein are for illustrative purposes only and should not be considered limiting.

[0010] A typical diesel exhaust fluid (DEF) anti-freeze system utilizes a temperature and ultrasonic level and concentration (TULC) sensor that includes a single temperature sensor located inside the DEF tank or container. Since the temperature is measured at only a single location within the DEF tank and may not, in some cases, indicate the uniform temperature of the entire DEF within the DEF tank, the TULC sensor provides local thawing performance. For example, an off-highway vehicle such as a mining truck may have a large engine (e.g., over 700 horsepower) and a DEF tank larger than 30, 60, 100, and 200 gallon tanks. In a large DEF tank, the local temperature measured by the TULC sensor may not necessarily indicate the DEF temperature of the entire DEF tank, especially at low temperatures (e.g., 0 degrees Fahrenheit). As previously mentioned, typically, DEF freezes at minus 12 degrees Celsius (-12°C) or 11 degrees Fahrenheit (11°F).

[0011] In a typical system, the temperature signal from the TULC sensor is used to activate a heat source applied to the DEF tank and other exhaust gas-related components. Accurate measurements are important to ensure that exhaust gas regulations are met.

[0012] Generally referring to the figures, the various aspects disclosed herein relate to systems, devices, and methods for improved thawing of DEF tanks. The DEF heating or thawing system includes a controller (e.g., an engine control module or a dedicated controller) that controls an electronically controlled coolant valve to selectively provide heated coolant from the engine to a heat exchanger positioned within the DEF tank to heat or thaw the DEF within the DEF tank when the temperature of the DEF within the DEF tank is below a predetermined temperature (e.g., 15 degrees Celsius). The controller receives temperature information from a TULC sensor positioned adjacent to the heat exchanger and a secondary temperature sensor array including one or more temperature sensors disposed within the DEF tank at an interval from the TULC sensor. The secondary temperature sensor array adjusted with respect to the TULC sensor processes all temperature signals and creates a temperature matrix used to provide a more accurate heating strategy and / or control of the DEF heating system. Using a pre-programmed model, algorithm, logic, or machine learning method, a temperature matrix can be created to provide a more accurate thermal model of the DEF within the DEF tank and, thus, more accurate control of the electronically controlled coolant valve to better maintain the temperature within the DEF tank or thaw the DEF within the DEF tank. The improved DEF heating system provides advantages including the removal of hot spots near the TULC sensor that can cause premature interruption of the coolant flow to the heat exchanger, thereby leaving some DEF within the DEF tank frozen. Another advantage of the more accurate thermal model is the elimination of misrepresentation of the amount of thawed DEF ready to be injected. The thermal model enables the aftertreatment system to more quickly and properly initiate dosing.

[0013] As shown in FIG. 1, a diesel exhaust fluid system in the form of a DEF heating system 10 includes an engine 14, a DEF tank 18, and a switching element in the form of an electronically controlled coolant valve 22 that controls the flow of energy to the DEF tank 18 to heat the DEF held within the DEF tank 18. In some embodiments, the switching element includes an electronic switch, a mechanically actuated valve, or other switching device. In some embodiments, the energy to heat the DEF tank 18 is provided by a generator, a battery, an auxiliary heating system, or another heat source other than the engine 14. Generally, the engine 14 generates heat that is absorbed by the coolant. The electronically controlled coolant valve 22 controls the flow of coolant to the DEF tank 18 to heat the DEF tank.

[0014] As shown in FIG. 2, the DEF tank 18 includes a header 26 constructed to enclose the DEF tank 18 and support a filter, a suction and fill tube for the DEF, a heating unit 30 that includes a heating element in the form of a heat exchanger 34, and a TULC sensor 38. In some embodiments, the heating element is a resistive heating element for water or another heating element as desired. The header 26 includes two heating units 30, 30' that are substantially identical. In some embodiments, more than three or less than two heating units 30 are included in the header 26. The heat exchanger 34 is fluidly coupled to the electronically controlled coolant valve 22 and selectively receives coolant heated by the engine 14. The heat exchanger 34 effects heat exchange between the DEF held within the DEF tank 18 and the coolant heated by the engine 14.

[0015] As shown in FIG. 3, the TULC sensor 38 is located in the center within the DEF tank 18. The DEF heating system 10 also includes a secondary sensor array 42 that includes a first temperature sensor 46, a second temperature sensor 50, a third temperature sensor 54, and a fourth temperature sensor 58. In some embodiments, the TULC sensor 38 includes a group of sensors that includes a level sensor, a quality sensor, and a first temperature sensor. In some embodiments, the secondary sensor array 42 includes five or more temperature sensors or less than four temperature sensors. For example, in a 30-gallon DEF tank, one temperature sensor within the secondary sensor array 42 may be sufficient, while a 100-gallon DEF tank may require five temperature sensors within the secondary sensor array 42. The secondary sensor array 42 is positioned to sense the temperature of the DEF within the DEF tank 18 at a location remote from the TULC sensor 38. For example, the corners of a large DEF tank 18 may not receive much heat circulation and may not be heated uniformly with most of the DEF within the DEF tank 18. The secondary sensor array 42 can position temperature sensors at remote corners to provide the temperature at the corners. As shown in FIG. 3, the four temperature sensors 46, 50, 54, 58 are positioned at the four corners of the generally rectangular DEF tank 18.

[0016] The TULC sensor 38 is communicatively coupled to an engine control module (ECM) 62 associated with the engine 14. The secondary sensor array 42 is coupled to a diesel exhaust fluid tank control system in the form of a controller 66 that communicates with the ECM 62. In some embodiments, the controller 66 is attached to the engine 14. In some embodiments, the controller 66 is attached remotely from the engine 14. The ECM 62 and the controller 66 adjust and develop a thermal model of the DEF tank 18. In some embodiments, the controller 66 is embodied as a module or circuit within the ECM 62. In some embodiments, the controller 66 is a separate controller located remotely from the ECM 62. In some embodiments, the ECM 62 and the controller 66 for multiple aspects are shared, distributed, or combined in a cloud-based control scheme.

[0017] As shown in FIG. 4, the TULC sensor 38 and the secondary sensor array 42 can communicate directly with the controller 66, and the controller 66 can communicate with the ECM 62 to control the electronically controlled coolant valve 22. In some embodiments, the controller 66 communicates directly with the electronically controlled coolant valve 22 without the intervention of the ECM 62.

[0018] Although the components of FIG. 1 are shown as being embodied within a vehicle including the DEF heating system 10, the controller 66 can be constructed as one or more electronic control units (ECUs). The controller 66 can be separate from or included in at least one of a transmission control unit, an exhaust aftertreatment control unit, a powertrain control module, an engine control module (e.g., ECM 62), etc. The function and structure of the controller 66 will be described in more detail with reference to FIG. 5.

[0019] Referring now to FIG. 5, a schematic diagram of the controller 66 of the DEF heating system 10 of FIG. 1 is shown according to an exemplary embodiment. As shown in FIG. 5, the controller 66 includes a processing circuit 70 having a processor 74 and a memory device 78, a control system 80 having a sensor circuit 84, an ECM circuit 88, a modeling engine 92, and a heating circuit 96, and a communication interface 100. Generally, the controller 66 is constructed to generate a thermal model of the DEF tank 18 and control the operation of the electronically controlled coolant valve 22.

[0020] In one configuration, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 are embodied as a machine-readable medium or a computer-readable medium that is executable by a processor such as the processor 74. The machine-readable medium, among other uses as described herein, facilitates the performance of certain operations to enable the transmission and reception of data. For example, the machine-readable medium may provide instructions (e.g., commands, etc.) for acquiring data. In this regard, the machine-readable medium may include programmable logic that defines the frequency of data acquisition (or data transmission). The computer-readable medium may include code written in any programming language, including but not limited to Java, and any conventional procedural programming language such as the "C" programming language or a similar programming language. The computer-readable program code may be executed on one processor or multiple remote processors. In the latter scenario, the remote processors may be connected to each other via any type of network (e.g., a CAN bus, etc.).

[0021] In another configuration, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 are embodied as a hardware unit, such as an electronic control unit. As such, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can be embodied as one or more circuit components including, but not limited to, a processing circuit, a network interface, peripheral devices, input devices, output devices, sensors, etc. In some embodiments, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can take the form of one or more analog circuits, electronic circuits (e.g., integrated circuit (IC), discrete circuit, system-on-chip (SOC) circuit, microcomputer, etc.), communication circuits, hybrid circuits, and any other type of "circuit". In this regard, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can include any type of component for implementing the operations described herein or facilitating the achievement of the operations. For example, the circuits 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 sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can also include programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices, etc. The sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can include one or more memory devices for storing instructions executable by the processors of the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96. The one or more memory devices and processors can have the same definitions as those provided below for the memory device 78 and the processor 74. In some hardware unit configurations, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can be geographically distributed throughout separate locations within the vehicle.Alternatively, as shown, the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can be embodied in or within a single unit / housing shown as the controller 66.

[0022] In the example shown, the controller 66 includes a processing circuit 70 having a processor 74 and a memory device 78. The processing circuit 70 can be constructed or configured to execute or implement the instructions, commands, and / or control processes described herein with respect to the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96. The configuration depicted represents the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 as a machine-readable medium or a computer-readable medium. However, as described above, in the present disclosure, other embodiments in which the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96, or at least one of the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 are configured as one hardware unit are also contemplated, so this example is not intended to be limiting. All such combinations and variations are intended to be included within the scope of the present disclosure.

[0023] The hardware and data processing components (e.g., processor 74) used to implement the various processes, operations, exemplary logic, logic blocks, modules, and circuits described in connection with the aspects disclosed herein can be implemented or carried out with a general - purpose single - chip processor or general - purpose multi - chip processor, a digital signal processor (DSP), an application - specific integrated circuit (ASIC), a field - programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. The general - purpose processor can be a microprocessor, or any conventional processor, or a state machine. The processor can also be implemented as a combination of computing devices such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors used in conjunction with a DSP core, or any other such configuration. In some aspects, one or more processors may be shared by a number of circuits (e.g., sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may, in some exemplary aspects, include the same processor that can execute instructions stored in different regions of memory or otherwise accessed or otherwise shared). Alternatively or additionally, one or more processors can be configured to perform or otherwise execute a particular operation independently of one or more coprocessors. In other exemplary aspects, two or more processors can be coupled via a bus to enable independent, parallel, pipelined, or multi - threaded instruction execution. All such variations are intended to be included within the scope of the present disclosure.

[0024] The memory device 78 (e.g., memory, memory unit, storage device) can include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and / or computer code for completing or facilitating the various processes, layers, and modules described in this disclosure. The memory device 78 can be communicatively connected to the processor 74 to provide computer code or instructions to the processor 74 for executing at least some of the processes described herein. Additionally, the memory device 78 can be or include tangible non-transitory volatile or non-volatile memory. Thus, the memory device 78 can 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.

[0025] The sensor circuit 84 is configured to collect temperature information from the TULC sensor 38 and the secondary sensor array 42 via the communication interface 100. In some aspects, the sensor circuit 84 manipulates the information provided by the TULC sensor 38 and the secondary sensor array 42 for use by the controller 66. For example, the sensor circuit 84 can average the temperature information of individual sensors (e.g., temperature sensors 46, 50, 54, 58), process the temperature information with a weighted average, or perform other processing.

[0026] The ECM circuit 88 is configured to communicate with the ECM 62 to coordinate operations therewith. In some aspects, the ECM circuit 88 is the ECM 62. In some aspects, the ECM circuit 88 controls the operation of the electronically controlled coolant valve 22 by providing communication with the ECM 62 via the communication interface 100. In some aspects, the sensor circuit 84 does not communicate directly with the TULC sensor 38, and the temperature information from the TULC sensor 38 is received by the ECM circuit 88.

[0027] The modeling engine 92 is constructed to generate a thermal model of the DEF tank 18 based on the temperature information received from the sensor circuit 84 and the ECM circuit 88. In some embodiments, the thermal model generates a three-dimensional heat map of the DEF tank 18 to determine where in the DEF tank 18 the DEF exceeds a predetermined threshold temperature and where in the DEF tank 18 the DEF is below the threshold temperature, and includes a machine learning method (such as reinforcement learning, neural network, etc.) that learns the relationship between the TULC sensor 38 and the secondary sensor array. In some embodiments, the thermal model is based on a pre-programmed model, algorithm, ladder logic, etc.

[0028] In some embodiments, the temperature indicated by the TULC sensor 38 is the primary temperature T1, and the temperature indicated by the secondary sensor array 42 is the secondary temperature T2. In some embodiments, a temperature (e.g., T2 - T5) is assigned to each individual sensor within the secondary sensor array 42. Then, the modeling engine 92 compares the primary temperature T1 with the secondary temperature T2 or all of the secondary temperatures T2 - T5 and returns the lowest temperature for use by the controller 66. For example, if the secondary temperature T2 is lower than the primary temperature T1, the thermal model returns the secondary temperature. In some embodiments, a weighted average is assigned to the temperatures T1 - T5 such that the sensors are given a priority. For example, the primary temperature T1 determined by the TULC sensor 38 can be the highest priority temperature. The modeling engine 92 can assign a predetermined range within which the primary temperature is returned. For example, if the threshold temperature is 15 degrees Celsius (15°C) and the range is 1 degree Celsius (1°C), the secondary temperature is returned when the secondary temperature is 14 degrees Celsius (14°C) or lower.

[0029] The heating circuit 96 receives the heat model and communicates with the electronically controlled coolant valve 22 to operate the electronically controlled coolant valve 22 between an open position where coolant is provided to the heat exchanger 34 and a closed position where flow of the coolant to the heat exchanger 34 is blocked. In some aspects, the electronically controlled coolant valve 22 is closed when the heat model indicates that the temperature of the DEF in the DEF tank 18 is at or above a threshold temperature (e.g., 15° C.) and is opened when the heat model indicates that the temperature of the DEF in the DEF tank 18 is below the threshold temperature (e.g., 15° C.). In some aspects, the heating circuit 96 communicates with the ECM 62 via the communication interface 100 to execute control of the electronically controlled coolant valve 22.

[0030] As shown in FIG. 6, a method 104 of operating the DEF heating system 10 includes receiving a primary temperature T1 from the TULC sensor 38 at step 108 and receiving a secondary temperature T2 from the secondary sensor array 42 at step 112. The controller 66 then generates a heat model at step 116. In some aspects, the heat model generated at step 116 is used directly (e.g., via a three-dimensional heat map) to determine parameters of the DEF (e.g., percentage and distribution of dissolved DEF, volume of dissolved DEF, temperature distribution, etc.), and the heat model is used directly to determine the operation of the electronically controlled coolant valve 22.

[0031] As shown in FIG. 6, controller 66 compares the primary temperature with the second temperature in step 120. If the primary temperature T1 is less than or equal to the secondary temperature T2, method 104 proceeds to step 124 where the primary temperature T1 is compared to a threshold temperature (e.g., 15° C.). If the primary temperature T1 is lower than (or equal to) the threshold temperature, the diesel exhaust fluid (DEF) pump cannot yet be primed and the DEF tank 18 must be thawed. In step 128, the electronically controlled coolant valve 22 is opened to heat the DEF within the DEF tank 18 and the method returns to steps 108 and 112. If in step 124 the primary temperature T1 is higher than (or equal to) the threshold temperature, method 104 proceeds to step 132 where controller 66 compares the secondary temperature T2 to the threshold temperature. If the secondary temperature T2 is higher than (or equal to) the threshold temperature, the DEF pump is primed in step 136. If in step 132 the secondary temperature T2 is lower than (or equal to) the threshold temperature, the electronically controlled coolant valve 22 is opened and the DEF is further heated. In some embodiments, step 132 is omitted.

[0032] If in step 120 the secondary temperature T2 is less than the primary temperature T1, method 104 proceeds to step 140 where the secondary temperature T2 is compared to the threshold temperature. If the secondary temperature T2 is lower than (or equal to) the threshold temperature, the electronically controlled coolant valve 22 is opened in step 128, and if the secondary temperature T2 is higher than (or equal to) the threshold temperature, the DEF pump is primed in step 136.

[0033] The systems and methods described above advantageously provide improved control of thawing and heating of DEF within a large DEF tank. For example, this control is particularly important in a DEF tank 18 larger than a 30 gallon tank where existing systems tend to have cold spots where the temperature of the DEF throughout the DEF tank 18 is misrepresented.

[0034] As shown in FIGS. 7A - 7D, the DEF tank 18 including the first heating unit 30 and the second heating unit 30' can be arranged in a direction facing the secondary sensors 46 and 50 which are arranged separately from the heat exchangers 34 and 34'. The position of the TULC 38 is located substantially at the center within the DEF tank 18 to reduce the influence of DEF sloshing within the DEF tank 18. However, the central position of the TULC 38 may lead to an inaccurate assessment of the state of DEF within the DEF tank 18 without adding a secondary sensor array 42 including the secondary sensors 46 and 50. FIGS. 8A - 8D show another aspect of the DEF tank 18 including two heating units 30 and 30' arranged substantially parallel and facing in the same direction. In some aspects, the DEF tank arrangements shown in FIGS. 7A - 7D and FIGS. 8A - 8D may include only one secondary sensor 46 or three or more secondary sensors. The heat exchangers 34, 34' are positioned in separate parts of the DEF tank 18 to apply heat to separate regions, volumes, or parts of the DEF tank 18 to thaw the DEF within the DEF tank 18 more uniformly. The separate parts of the DEF tank 18 do not overlap. The heat exchangers 34, 34' are arranged in separate parts so as not to overlap. In some aspects, the first heating element including the heat exchanger 34 is positioned in the first part of the diesel exhaust fluid tank 18, and the second heating element including the heat exchanger 34' is positioned in the second part of the diesel exhaust fluid tank 18 that does not overlap with the first part.

[0035] As used herein, the terms "substantially", "about", "essentially", and similar terms are intended to have a broad meaning consistent with the ordinary and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of ordinary skill in the art considering this disclosure that these terms are intended to enable the description of the specific features being described and claimed without restricting the scope provided for these features to the exact numerical ranges. Thus, these terms should be construed to indicate that non - essential or insignificant modifications or variations to the subject matter being described and claimed are considered to be within the scope of the disclosure set forth in the appended claims.

[0036] As used herein to describe various aspects, the term "exemplary" and variations thereof are intended to indicate that such aspects are possible examples, representations, or illustrations of possible manners (and such terms are not intended to imply that such aspects are necessarily special or the best examples). It should be noted that this is the case.

[0037] As used herein, the term "coupled" and variations thereof mean that two members are joined directly or indirectly to each other. Such joining can be in a stationary state (e.g., permanent or fixed) or a movable state (e.g., removable or releasable). Such joining can be achieved by two members directly joined to each other, by two members joined to each other using one or more separate intermediate members, or by two members joined to each other using an intermediate member integrally formed as a single unit with one of the two members. When "coupled" or variations thereof are modified by additional terms (e.g., directly coupled), the general definition of "coupled" provided above is modified by the plain meaning of the additional term (e.g., "directly coupled" means the joining of two members without any separate intermediate members), resulting in a definition narrower than the general definition of "coupled" provided above. Such coupling can be mechanical, electrical, or fluidic. For example, circuit A "coupled" communicably to circuit B can mean that circuit A communicates directly with circuit B (i.e., without an intermediary means) or communicates indirectly with circuit B (e.g., via one or more intermediary means).

[0038] References in this specification to the position of elements (e.g., "top", "bottom", "above", "below", etc.) are used merely to describe the orientation of the various elements in the figures. It should be noted that the orientations of the various elements may vary according to other exemplary aspects, and such variations are intended to be encompassed by the present disclosure.

[0039] Although various circuits with specific functions are shown in FIG. 5, it should be understood that the controller 66 can include any number of circuits for accomplishing the functions described herein. For example, the activities and functions of the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96 can be combined in a number of circuits or as a single circuit. Additional circuits with additional functions can also be included. Further, the controller 66 can further control other activities beyond the scope of the present disclosure.

[0040] As described above, in one configuration, a “circuit” can be implemented in a machine-readable medium for execution by various types of processors, such as the processor 74 of FIG. 5. The identified circuit of executable code can include, for example, one or more physical or logical blocks of computer instructions, which can be organized as, for example, objects, procedures, or functions. Nevertheless, the executable code of the identified circuit need not be physically located together, but when logically coupled to each other, can include instructions stored in different locations that, together with the circuit, achieve the above-described purpose of the circuit. In fact, the circuit of computer-readable program code can be a single instruction, or many instructions, and can further be distributed among several different code segments, among several different programs, and across several memory devices. Similarly, the operational data can be identified and exemplified herein within the circuit, can be embodied in any suitable form, and can be organized within any suitable type of data structure. The operational data can be collected as a single data set or can be distributed in different locations including different storage devices and can exist, at least in part, simply as electronic signals on a system or network.

[0041] The term "processor" has been briefly defined above, but the terms "processor" and "processing circuit" are intended to be construed broadly. In this regard, as noted above, a "processor" can be implemented as one or more general-purpose 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. 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, one or more processors can be external to the device; for example, one or more processors can be remote processors (e.g., cloud-based processors). Alternatively or additionally, one or more processors can be present inside and / or locally to the device. In this regard, a given circuit or component can be located locally (e.g., as part of a local server, a local computing system, etc.) or remotely (e.g., as part of a remote server such as a cloud-based server). For this purpose, the "circuits" described herein can include components that are distributed across one or more locations overall.

[0042] Aspects within the scope of the present disclosure include a program product that includes a machine-readable medium for holding or having stored machine-executable instructions or data structures. Such a machine-readable medium can be any available medium that can be accessed by a general-purpose or special-purpose computer or by other machines equipped with a processor. By way of example, such a machine-readable medium can be RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to hold or store desired program code in the form of machine-executable instructions or data structures and that can be accessed by a general-purpose or special-purpose computer or by other machines equipped with a processor. Combinations of the foregoing are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data for causing a particular function or group of functions to be performed on a general-purpose computer, special-purpose computer, or special-purpose processing machine.

[0043] The figures and the description may indicate a specific order of method steps, but such order may differ from that depicted and described, unless otherwise specified above. Also, unless otherwise specified above, two or more steps may be performed simultaneously or partially simultaneously. Such variations may depend, for example, on the selected software and hardware systems and on the designer's choices. All such variations are within the scope of the present disclosure. Similarly, the software implementation of the described methods can be realized using standard programming techniques using rule-based logic and other logic to implement various connection steps, processing steps, comparison steps, and decision steps.

[0044] It is important to note that the configurations and arrangements of the DEF heating system 10 shown in the various exemplary aspects are merely exemplary. Additionally, any element disclosed in one aspect can be combined with or utilized with any other aspect disclosed herein. For example, the controller 66 of the exemplary aspect can be incorporated into the ECM 62 of the exemplary aspect. Although only one example of an element of one aspect that can be incorporated into or utilized in another aspect has been described above, it should be understood that other elements of the various aspects can be combined with or utilized with any of the other aspects disclosed herein.

Claims

1. a diesel exhaust fluid tank, a first temperature sensor positioned within the diesel exhaust fluid tank and configured to provide first temperature information indicative of a first temperature, a second temperature sensor positioned within the diesel exhaust fluid tank and configured to provide second temperature information indicative of a second temperature, one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices storing instructions that, when executed by the one or more processors, cause the one or more processors to provide energy to a heating system based on the first temperature information and the second temperature information wherein the one or more processing circuits are configured to store the instructions, a diesel exhaust fluid system including the same.

2. The diesel exhaust fluid system of claim 1, wherein the one or more processing circuits further include an engine control module configured to receive the first temperature information.

3. wherein the one or more memory devices are further configured to store instructions that, when executed by the one or more processors, cause the one or more processors to generate a thermal model of the diesel exhaust fluid tank, and wherein energy is provided to the heating system when the diesel exhaust fluid within the diesel exhaust fluid tank is above a predetermined threshold as indicated by the thermal model. The diesel exhaust fluid system of claim 1.

4. wherein the one or more memory devices are further configured to store instructions that, when executed by the one or more processors, cause the one or more processors to provide energy to a heating element when (i) the first temperature is above a predetermined threshold and the second temperature is within a predetermined range from the first temperature, or (ii) the second temperature is above the predetermined threshold and the second temperature is not within the predetermined range from the first temperature. The diesel exhaust fluid system of claim 1.

5. The diesel exhaust fluid system of claim 1, wherein the diesel exhaust fluid tank is 30 gallons or more.

6. further including an exhaust fluid tank header, wherein the exhaust fluid tank header supports each of the heating system, the first temperature sensor, and the second temperature sensor. ​ The diesel exhaust fluid system according to claim 1.

7. The diesel exhaust fluid system according to claim 1, further comprising a group of sensors including a level sensor, a quality sensor, and a first temperature sensor.

8. A third temperature sensor positioned within the diesel exhaust fluid tank and configured to provide third temperature information indicative of a third temperature; A fourth temperature sensor positioned within the diesel exhaust fluid tank and configured to provide fourth temperature information indicative of a fourth temperature; A fifth temperature sensor positioned within the diesel exhaust fluid tank and configured to provide fifth temperature information indicative of a fifth temperature The diesel exhaust fluid system according to claim 7, further comprising.

9. The one or more processing circuits further include an engine control module configured to receive the first temperature information from the combined sensor, The one or more memory devices, When executed by the one or more processors, Receiving the first temperature information from the engine control module; Receiving the second temperature information from the second temperature sensor; Receiving the third temperature information from the third temperature sensor; Receiving the fourth temperature information from the fourth temperature sensor; Receiving the fifth temperature information from the fifth temperature sensor; Generating a thermal model of the diesel exhaust fluid tank based on the first temperature information, the second temperature information, the third temperature information, the fourth temperature information, and the fifth temperature information Instructions to cause the one or more processors to perform Further configured to store. The diesel exhaust fluid system according to claim 8.

10. The diesel exhaust fluid system according to claim 1, further comprising the heating system, the heating system including a heating element.

11. The diesel exhaust fluid system according to claim 10, wherein the heating element includes a heat exchanger configured to receive coolant from an engine.

12. The heating system is further included, The heating system is, A first heating element positioned at a first portion of the diesel exhaust fluid tank; A second heating element positioned at a second portion of the diesel exhaust fluid tank that does not overlap with the first portion The diesel exhaust fluid system according to claim 1, including.

13. The one or more memory devices, When executed by the one or more processors, generating a three-dimensional heat map based on the first temperature information and the second temperature information; providing energy to the heating system based on the three-dimensional heat map and causing the one or more processors to perform the above operations, The diesel exhaust fluid system according to claim 1, further configured to store the instructions. **Claim 14** When the one or more memory devices are executed by the one or more processors, comparing the first temperature with the second temperature; comparing the first temperature with a predetermined threshold; comparing the second temperature with the predetermined threshold; when the first temperature is less than or equal to the second temperature and the first temperature is less than or equal to the predetermined threshold, or when the second temperature is less than or equal to the predetermined threshold, providing energy to the heating system and causing the one or more processors to perform the above operations, The diesel exhaust fluid system according to claim 1, further configured to store the instructions. **Claim 15** When the one or more memory devices are executed by the one or more processors, causing the one or more processors to transmit a signal permitting operation of the diesel exhaust fluid pump when the second temperature is higher than the predetermined threshold. The diesel exhaust fluid system according to claim 14, further configured to store the instructions. **Claim 16** A diesel exhaust fluid tank control system for use with a diesel exhaust fluid tank including a temperature and ultrasonic level and concentration (TULC) sensor and a heating system, the system comprising: a temperature sensor array positioned within the diesel exhaust fluid tank and constructed to provide temperature information; and 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 that, when executed by the one or more processors, cause the one or more processors to provide energy to the heating system based on the temperature information. The one or more processing circuits are configured as described above. **Claim 17** When the one or more memory devices are When executed by the one or more processors, determine a secondary temperature based on the temperature information received from the temperature sensor array; send a signal permitting operation of the diesel exhaust fluid pump when the secondary temperature is higher than a predetermined threshold; instructions causing the one or more processors to perform the above; The diesel exhaust fluid tank control system according to claim 16, further configured to store the instructions. **Claim 18** When the one or more memory devices are executed by the one or more processors, receive TULC temperature information indicating a TULC temperature from the TULC sensor; determine a secondary temperature based on the temperature information received from the temperature sensor array; compare the TULC temperature with the secondary temperature; compare the TULC temperature with the predetermined threshold; compare the secondary temperature with the predetermined threshold; provide energy to the heating system when the TULC temperature is less than or equal to the secondary temperature and the TULC temperature is less than or equal to the predetermined threshold, or when the secondary temperature is less than or equal to the predetermined threshold; instructions causing the one or more processors to perform the above; The diesel exhaust fluid tank control system according to claim 16, further configured to store the instructions. **Claim 19** receiving primary temperature information indicating a primary temperature from a first temperature sensor positioned within the diesel exhaust fluid tank; receiving secondary temperature information indicating a secondary temperature from a temperature sensor array positioned within the diesel exhaust fluid tank; selectively providing energy to a heating system positioned within the diesel exhaust fluid tank based on the primary temperature and the secondary temperature; A method comprising the above steps. **Claim 20** comparing the primary temperature with the secondary temperature; comparing the primary temperature with a predetermined threshold; comparing the secondary temperature with the predetermined threshold; providing energy to the heating system when the primary temperature is less than or equal to the secondary temperature and the primary temperature is less than or equal to the predetermined threshold, or when the secondary temperature is less than or equal to the predetermined threshold; The method according to claim 19, further comprising the above steps.

Images