Air Filter Loading Estimation Using Mass Air Flow and Temperature

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Solution Overview

Problem

Current methods for monitoring air filter loading in engines require two air pressure sensors, increasing cost and complexity, and seek a more economical and simpler approach.

Innovation Solution

A system that estimates air filter loading by using a mass air flow sensor on the upstream side, an air pressure sensor and a temperature sensor on the downstream side, and a processing system to calculate differential pressure based on mass air flow, air pressure, and temperature data, adapting to both laminar and turbulent pressure losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If two air pressure sensors are used to measure differential pressure across the air filter, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improvedifferential pressure measurementVSAvoidsensor system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The invention extracts only the necessary measurement from the two-sensor system. Instead of measuring both upstream and downstream pressures directly, it measures only downstream pressure and calculates upstream pressure indirectly through mass air flow and temperature data, eliminating the need for a second pressure sensor

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention introduces mass air flow and temperature data as intermediary parameters to bridge the gap between downstream pressure measurement and upstream pressure estimation. These intermediaries enable calculation of the differential pressure without direct measurement on both sides

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If two air pressure sensors are installed on both sides of the air filter, then measurement accuracy is improved, but system cost increases

Engineering Contradiction:

Improvefilter loading monitoringVSAvoidsystem cost

Core Design Contradiction:

Measurement precisionVSQuantity of substance

Solution Approach 1:

The invention replaces expensive pressure sensors with more economical sensors (mass air flow and temperature sensors) combined with computational processing. This substitution maintains measurement capability while reducing system cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention substitutes a purely mechanical measurement system (two pressure sensors) with a hybrid system combining sensors and computational processing. The processing system calculates upstream pressure from mass air flow and temperature data, replacing the need for mechanical pressure measurement on both sides

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces system complexity and cost while accurately estimating air filter loading, allowing for easy calibration and providing timely indications for filter replacement, maintaining accuracy across various debris loads and engine conditions.

Implementation Method 1

receiving upstream mass air flow data indicative of a mass air flow on an upstream side of an air filter

Methodology Applied

Scientific EffectMass air flow measurement:

Implementation Method 2

receiving downstream air pressure data indicative of an air pressure on a downstream side of the air filter

Methodology Applied

Scientific EffectAir pressure measurement:

Implementation Method 3

receiving downstream temperature data indicative of a temperature on the downstream side of the air filter

Methodology Applied

Scientific EffectTemperature measurement:

Implementation Method 4

determining a differential pressure (ΔP) across the air filter indicative of a loading of the air filter based on the upstream mass air flow data, the downstream air pressure data, and the downstream temperature data

Methodology Applied

Scientific EffectDifferential pressure calculation:

Data Source

PatentUS9983114B2Methods and systems for monitoring loading of an air filter

Publication Date: 2018.05.29 CUMMINS INC

AI summary

Methods and systems for estimating the loading of an air filter are disclosed herein. The method includes receiving upstream mass air flow data indicative of a mass air flow on an upstream side of an air filter (i.e., the “dirty side of the filter”), receiving downstream air pressure data indicative of an air pressure on a downstream side of the air filter (i.e., the “clean side of the filter”), and receiving downstream temperature data indicative of a temperature on the downstream side of the air filter. The method also includes determining a differential pressure (ΔP) across the air filter indicative of a loading of the air filter based on the upstream mass air flow data, the downstream air pressure data, and the downstream temperature data.