Centralized Controller for Multi-Bank Reductant Injection
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Solution Overview
Problem
Conventional exhaust aftertreatment systems for large IC engines face complexity and slow response to variable operating conditions due to multiple controllers managing reductant insertion assemblies, leading to increased emissions and difficulty in meeting stringent NOx emission requirements.
Innovation Solution
Implementing a parent controller communicatively coupled to multiple child controllers to centrally manage reductant insertion assemblies across multiple banks, reducing the number of electronic components and ensuring continuous reductant insertion even if one or more child controllers fail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple controllers are used to control individual reductant insertion assemblies in each bank, then each bank can be controlled independently, but the system complexity increases and response speed decreases
Solution Approach 1:
The patent consolidates multiple individual controllers into a single centralized controller that manages all reductant insertion assemblies across multiple banks. This single controller integrates the functions of what would otherwise require separate controllers for each bank, reducing system complexity while maintaining the ability to independently control reductant injection in each bank through software-based bank identification and control logic
2Reliability
If multiple controllers are used to manage reductant insertion assemblies, then comprehensive control is achieved, but the response time to variable operating conditions becomes slower
Solution Approach 1:
The centralized controller consolidates control functions into a single processing unit, eliminating communication delays between multiple distributed controllers. This unified architecture processes operating condition changes and coordinates reductant injection across all banks more rapidly, improving response time while maintaining comprehensive control through centralized monitoring and actuation of all injection assemblies
3Adaptability or versatility
If multiple controllers are implemented in the aftertreatment system, then individual bank control is improved, but manufacturing and maintenance costs increase
Solution Approach 1:
The patent reduces the total number of controllers from multiple individual units to a single centralized controller, directly lowering component count and manufacturing costs. The single controller design also simplifies maintenance requirements and reduces system integration complexity, while still enabling independent control of each bank through software-based bank identification and control logic that manages multiple reductant insertion assemblies
Data Source
AI summary
An aftertreatment system comprises a first bank to receive a first portion of an exhaust gas and a second bank to receive a second portion of the exhaust gas. A first reductant insertion assembly is fluidly coupled to the first bank and a parent controller is communicatively coupled thereto. A second reductant insertion assembly is fluidly coupled to the second bank and a first child controller is communicatively coupled thereto. A third reductant insertion assembly is fluidly coupled to the first bank and a second child controller is communicatively coupled thereto. The parent controller instructs the first reductant insertion assembly to insert reductant into the first bank. The parent controller also instructs the first child controller to command the second reductant insertion assembly to insert reductant into the second bank, and instructs the second child controller to command the third reductant insertion assembly to insert reductant into the first bank.