Air-Assisted Fuel Dosing Module for DPF Regeneration
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Solution Overview
Problem
Existing filtration systems for internal combustion engines face challenges in continuously removing particles from dosing lines and nozzles, leading to coking and fouling, and require complex control systems for reliable DPF regeneration.
Innovation Solution
An air-assisted fuel dosing module (FDM) is integrated into the DPF system, which continuously removes particles by generating an air-fuel mixture that flows through the dosing line, using a simplified control system with fewer components, and oscillating the fuel valve to create transient conditions for re-entrainment of contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diesel fuel is dosed upstream of the DOC to raise temperature for DPF regeneration, then regeneration effectiveness is improved, but particle accumulation in the dosing line and nozzle increases leading to coking and fouling
Solution Approach 1:
The system introduces air continuously into the dosing line upstream of the nozzle to maintain continuous particle removal throughout the dosing process, rather than relying on periodic purging cycles. This continuous air injection prevents particle accumulation and coking while the fuel dosing raises temperature for DPF regeneration.
Solution Approach 2:
Air is introduced as an intermediary substance into the dosing line to facilitate particle removal. The air acts as a carrier gas that entrains particles and transports them through the dosing line and nozzle, preventing accumulation without interfering with the fuel dosing function.
2Object-affected harmful factors
If a separate purging system is added to remove particles from the dosing line, then particle removal capability is improved, but system complexity increases
Solution Approach 1:
The particle removal function is merged with the existing fuel dosing system by introducing air through the same dosing line infrastructure. The air injection points and control mechanisms are integrated into the existing fuel dosing module, eliminating the need for separate purging lines and control systems.
Solution Approach 2:
The dosing line infrastructure is made multi-functional by introducing air through it for particle removal purposes in addition to its primary function of fuel delivery. This allows the same physical infrastructure to serve dual purposes: fuel dosing for temperature rise and air-assisted particle removal.
3Object-affected harmful factors
If the fuel valve is oscillated to generate air-fuel fluid for particle removal, then particle re-entrainment capability is improved, but control complexity increases
Solution Approach 1:
The fuel valve is oscillated between open and closed positions at controlled frequencies to generate periodic air-fuel fluid pulses. This periodic action creates transient conditions that enhance particle re-entrainment from the dosing line walls, and the oscillation frequency can be adjusted based on operating conditions.
Solution Approach 2:
The fuel valve transitions from a static fully-open or fully-closed position to a dynamic oscillating position, creating time-varying flow conditions. This dynamic operation generates transient fluid behavior that enhances particle dislodgement and re-entrainment compared to steady-state operation.
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
This approach maintains doser cleanliness, reduces nozzle deposits, enhances fuel atomization and combustion, and simplifies system complexity by eliminating the need for separate purging modes, ensuring continuous particle removal and efficient DPF regeneration.
Implementation Method 1
The fuel valve is oscillated by opening and closing at a frequency, thereby generating an air-fuel fluid
Implementation Method 2
The air-fuel fluid removes particles from along the dosing line and the nozzle
Implementation Method 3
The fuel dosing module is configured to combine the fuel and the air upstream of the outlet and downstream of the fuel valve to generate an air-fuel fluid
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Various example embodiments relate to a system that includes a nozzle. A dosing line is connected to the nozzle and a fuel dosing module. The fuel dosing module is in fluid communication with the dosing line and includes an outlet in fluid communication with the dosing line. An air inlet is positioned upstream of the outlet and is configured to receive air. A fuel inlet is positioned upstream of the outlet and is configured to receive fuel. A fuel valve is positioned upstream of the outlet and downstream of the fuel inlet and is configured to control the flow of fuel. The fuel dosing module is configured to combine the fuel and the air upstream of the outlet and downstream of the fuel valve to generate an air-fuel fluid, wherein the air-fuel fluid removes particles from the nozzle.