Safety-Compliant Catalyst Heating Control via Dual ECU Segmentation
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Solution Overview
Problem
Existing aftertreatment catalyst heating systems for internal combustion engines face challenges related to complexity, cost, reliability, and safety, necessitating the development of safer and more efficient heating solutions.
Innovation Solution
The implementation of a safety-compliant catalyst heating aftertreatment system that includes a prime mover system with an electronic control system featuring a first electronic control unit configured to drive a heater and a second unit configured to enable and disable the first unit based on feedback, ensuring functional safety requirements are met, while the first unit does not satisfy these requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heater is used to heat the aftertreatment catalyst, then the catalyst temperature is increased to improve emission treatment efficiency, but safety risks increase due to potential overheating and uncontrolled operation
Solution Approach 1:
A second electronic control unit acts as an intermediary safety controller between the power source and the heater. This mediator monitors system conditions and controls the heater operation to prevent unsafe conditions, resolving the contradiction between achieving high catalyst temperature and ensuring system safety.
Solution Approach 2:
The system implements feedback control where the second electronic control unit continuously monitors heater operation and system state, adjusting heater control based on temperature sensors and operational conditions. This feedback mechanism ensures the catalyst reaches necessary temperatures while preventing overheating and maintaining safety.
2Reliability
If a complex electronic control system with multiple control units is implemented to ensure safety, then system safety is improved, but device complexity increases
Solution Approach 1:
The electronic control system is segmented into two distinct control units with clearly defined roles: the first control unit manages heater operation for catalyst heating, while the second control unit handles safety monitoring and control. This segmentation allows each unit to be optimized for its specific function, improving safety without requiring a completely redesigned complex 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 enhances the safety and reliability of catalyst heating systems by enabling controlled and safe operation of the heater, reducing the risk of faults and improving overall system performance.
Implementation Method 1
a heater configured to selectably heat the aftertreatment system
Data Source
AI summary
A power converter apparatus includes a parent circuit board comprising a first surface, a second surface, and a thermal conductor core disposed intermediate the first surface and the second surface. A first child circuit is board mounted on the parent circuit board. A first plurality of power switches are mounted on the first child circuit board. A second child circuit is board mounted on the parent circuit board. A second plurality of power switches are mounted on the second child circuit board. A first heat transfer circuit includes a first set of conductors thermally conductively coupling the first plurality of power switches with the thermal conductor core. A second heat transfer circuit includes a second set of conductors thermally conductively coupling the second plurality of power switches with the thermal conductor core.