Aftertreatment Regeneration Control With Predictive Hydrocarbon Dosing

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Solution Overview

Problem

Existing aftertreatment systems face inefficiencies and longevity issues due to residue accumulation, which current control methods like PID controllers fail to manage effectively, particularly in controlling the hydrocarbon dosing for regeneration processes.

Innovation Solution

Implementing a model predictive controller (MPC) that uses temperature sensors and a system model to predict future states of the aftertreatment system, generating optimal control commands for the hydrocarbon doser to achieve targeted temperature and duration efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a PID controller is used to control hydrocarbon dosing for aftertreatment regeneration, then the control method is simple and easy to implement, but the system efficiency deteriorates due to inability to effectively manage residue accumulation and temperature control

Engineering Contradiction:

Improvecontrol implementation simplicityVSAvoidregeneration process efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The model predictive controller performs preliminary actions by predicting future temperature states and optimizing hydrocarbon dosing commands in advance, rather than merely reacting to current temperature deviations. This anticipatory control enables the system to proactively manage the regeneration process, improving efficiency while maintaining operational simplicity through automated optimization.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If a PID controller is used for aftertreatment regeneration, then the device complexity is low, but the system reliability deteriorates due to ineffective residue management

Engineering Contradiction:

Improvecontroller structure simplicityVSAvoidregeneration process effectiveness

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The model predictive controller transforms the control approach by changing from fixed gain parameters (PID) to dynamic, optimized control parameters that adapt to varying system conditions. By continuously optimizing hydrocarbon dosing based on predicted temperature trajectories and system state, the controller achieves reliable residue management while maintaining reasonable device complexity through software-based optimization.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If hydrocarbon dosing is increased to ensure complete residue burn-off, then the regeneration effectiveness is improved, but fuel consumption increases

Engineering Contradiction:

Improveregeneration completenessVSAvoidfuel waste

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The model predictive controller applies partial action by optimizing hydrocarbon dosing to provide exactly the amount needed for effective regeneration, avoiding excessive fuel injection. By predicting future temperature states and system response, the controller determines the minimum necessary dosing to achieve complete residue burn-off, thereby reducing fuel waste while maintaining regeneration effectiveness.

Inventive Principle:

Principle #16Partial or excessive action

4Productivity

If the aftertreatment system operates at higher temperatures to burn residue faster, then the regeneration speed is improved, but the risk of overheating and system damage increases

Engineering Contradiction:

Improveregeneration speedVSAvoidoverheating risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The model predictive controller applies preliminary anti-action by predicting future temperature states and preemptively adjusting hydrocarbon dosing to prevent overheating before it occurs. The controller optimizes the dosing strategy to achieve rapid residue burn-off while incorporating safety constraints that prevent temperature from exceeding damaging thresholds, thus protecting the system while maintaining fast regeneration.

Inventive Principle:

Principle #9Preliminary anti-action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The MPC system ensures safer and more efficient aftertreatment regeneration by anticipating system dynamics, preventing overheating or underheating, thereby extending system life and reducing fuel waste.

Implementation Method 1

receive temperature information generated by the temperature sensor

Methodology Applied

Scientific EffectThermal energy detection: Thermocouple

Implementation Method 2

a hydrocarbon doser injects a small amount of fuel into the aftertreatment system, which combusts and causes the aftertreatment system to generate enough heat

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12540570B2Model predictive control for aftertreatment regeneration

Publication Date: 2026.02.03 CATERPILLAR INC

AI summary

In one instance, disclosed herein is an aftertreatment regeneration system comprising: an aftertreatment system; a temperature sensor operative to monitor a temperature of the aftertreatment system; a hydrocarbon doser operatively coupled to the aftertreatment system; and a model predictive controller operative to: receive an aftertreatment regeneration request; receive temperature information generated by the temperature sensor; generate, based on the aftertreatment regeneration request and the temperature information generated by the temperature sensor, a predicted future state of the aftertreatment system; and generate, based on the aftertreatment regeneration request, the temperature information generated by the temperature sensor, and the predicted future state of the aftertreatment system, a control command for actuating the hydrocarbon doser.