Diesel Exhaust Fluid Pressure Monitoring for Blockage Prevention
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Solution Overview
Problem
Existing diesel exhaust fluid (DEF) systems face issues with dehydration and crystallization, leading to blockages and performance hindrances, as they lack effective monitoring of valve operations and reductant presence in undesired areas.
Innovation Solution
A DEF delivery system with pressure sensors and a controller that manages valve states to ensure proper fluid flow and pressure management, preventing blockages and over-priming by monitoring fluid pressures and taking corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure sensors and valve control mechanisms are added to monitor DEF location, then system reliability improves, but device complexity increases
Solution Approach 1:
The system divides the DEF monitoring function into multiple pressure sensors placed at different locations (upstream and downstream of the injector) to detect DEF presence in specific zones. This segmentation allows reliable detection of DEF location without requiring a single complex monitoring system.
Solution Approach 2:
Pressure sensors serve as intermediary devices that indirectly detect DEF presence by measuring pressure changes in the fluid lines, rather than directly observing DEF crystals or fluid flow. This intermediary approach provides reliable information while keeping the monitoring system relatively simple.
2Measurement precision
If multiple pressure sensors are installed to detect DEF presence, then measurement precision improves, but device complexity increases
Solution Approach 1:
The monitoring system segments the DEF flow path into distinct zones by placing pressure sensors at different locations. The first pressure sensor monitors pressure upstream of the injector while the second sensor monitors pressure downstream, enabling precise determination of DEF presence in specific segments of the system.
Solution Approach 2:
The system replaces direct visual inspection or complex chemical sensing mechanisms with pressure measurement technology. Pressure sensors provide precise information about DEF presence by detecting pressure differentials, substituting more complex monitoring approaches with simpler mechanical pressure detection.
3Reliability
If the system continuously monitors pressure to detect DEF location, then reliability improves, but energy consumption increases
Solution Approach 1:
The controller performs periodic pressure measurements rather than continuous monitoring. The system evaluates pressure data at specific intervals or at key moments in the DEF dosing cycle, maintaining reliable detection capability while reducing overall energy consumption compared to continuous real-time monitoring.
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
The system effectively prevents blockages and performance issues by ensuring proper fluid flow and pressure management, reducing the risk of system failure due to dehydration and crystallization.
Implementation Method 1
a first pressure sensor configured to determine fluid pressure at a first location in the flow line between the pump and the injector and a second pressure sensor configured to determine fluid pressure at a second location in the flow line between the pump and the injector
Implementation Method 2
a pump fluidly connected to a fluid reservoir, the pump configured to direct diesel exhaust fluid (DEF) from the fluid reservoir to an injector
Implementation Method 3
an air source coupled to the injector via an air flow line, the air source configured to direct air to the injector via the air flow line
Data Source
AI summary
A system including a pump fluidly connected to a fluid reservoir, the pump configured to direct diesel exhaust fluid (DEF) from the fluid reservoir to an injector fluidly connected to the pump via a flow line. The system also includes a first pressure sensor configured to determine fluid pressure at a first location in the flow line between the pump and the injector and a second pressure sensor configured to determine fluid pressure at a second location in the flow line between the pump and the injector. The system further includes an air source coupled to the injector via an air flow line, the air source configured to direct air to the injector via the air flow line and a controller communicatively coupled to the first pressure sensor, the second pressure sensor, and the air source, the controller configured to diagnose the system.