Construction Machine Exhaust Regeneration Control
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Solution Overview
Problem
Construction machines experience frequent alternation between regeneration and regular operations due to insufficient exhaust gas temperature during light-load work or low rotational states, leading to increased fuel consumption, particulate matter accumulation, and operator discomfort.
Innovation Solution
A system with a temperature detector, PM calculating unit, regeneration start determining unit, interruption determining unit, and restart determining unit to manage regeneration treatment based on exhaust gas temperature and particulate matter accumulation, ensuring efficient burning and removal of particulate matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If regeneration treatment is executed during light-load work or low rotational state, then particulate matter removal is performed, but exhaust gas temperature is insufficient and regeneration efficiency deteriorates
Solution Approach 1:
The system continuously monitors exhaust gas temperature and particulate matter accumulation amount, using this feedback to dynamically adjust regeneration treatment execution. When temperature is insufficient despite PM accumulation, the control unit suppresses regeneration, preventing ineffective treatment cycles.
Solution Approach 2:
The system changes the operational parameters of regeneration treatment based on detected conditions. By monitoring exhaust gas temperature and PM accumulation amount as key parameters, the system adjusts whether to execute, interrupt, or suppress regeneration treatment to optimize effectiveness.
2Reliability
If regeneration treatment is repeatedly executed during low temperature periods, then particulate matter accumulation is addressed, but fuel consumption increases
Solution Approach 1:
The control unit uses feedback from temperature sensors and PM accumulation measurements to determine when regeneration should be executed. By suppressing regeneration when temperature is below the threshold, the system avoids unnecessary fuel injection and associated energy consumption.
Solution Approach 2:
Instead of executing complete regeneration cycles during unsuitable conditions, the system applies partial action by suppressing or interrupting regeneration treatment. This prevents excessive fuel consumption while still allowing regeneration to proceed when conditions are appropriate.
3Reliability
If regeneration treatment is executed frequently, then particulate matter is removed, but operator comfort deteriorates due to engine sound changes
Solution Approach 1:
The system monitors operational conditions including engine load and temperature to determine optimal regeneration timing. By suppressing regeneration during light-load operations, the system reduces frequent engine sound changes that would disturb the operator.
Solution Approach 2:
The system implements periodic regeneration treatment based on accumulated PM levels and temperature conditions rather than continuous or frequent regeneration. This spacing of regeneration events reduces the frequency of engine sound changes and improves operator comfort.
4Reliability
If post injection is performed frequently for regeneration, then particulate matter burning is enhanced, but engine oil dilution increases
Solution Approach 1:
The control unit monitors both PM accumulation and exhaust gas temperature to determine when post injection should be performed. By suppressing post injection when temperature is insufficient, the system prevents fuel from falling into the oil pan and mixing with engine oil.
Solution Approach 2:
The system applies partial action by selectively performing post injection only when temperature conditions are suitable. This prevents excessive fuel injection that would lead to oil dilution, while still achieving adequate PM burning when conditions permit.
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 fuel consumption, prevents excessive particulate matter accumulation, minimizes engine oil dilution, and enhances operational stability and reliability by optimizing regeneration treatment timing based on temperature and particulate matter levels.
Implementation Method 1
a temperature detector that detects a temperature of an exhaust gas discharged from the engine
Implementation Method 2
fuel injection for regeneration treatment called 'post injection' is performed to increase a temperature of an exhaust gas for burning the particulate matter that is accumulated in the filter
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A regeneration device (22) executes regeneration treatment of a filter (21) in an exhaust gas purifying device (18) by burning particulate matter trapped in the filter (21). The regeneration device (22) interrupts the regeneration treatment of the filter (21) when an exhaust gas temperature T detected by an exhaust gas temperature sensor (26) becomes less than an exhaust gas temperature threshold Tt during a period of performing the regeneration treatment of the filter (21). In a case where the regeneration treatment of the filter (21) is interrupted, when the exhaust gas temperature T becomes equal to or more than the exhaust gas temperature threshold Tt, the regeneration treatment of the filter (21) is restarted.