Diesel Particulate Filter Cleaning Machine with Soaking and Rinsing
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Solution Overview
Problem
Current diesel particulate filter (DPF) cleaning methods are inefficient, damaging, and costly, requiring lengthy high-temperature kiln baking or high-pressure water/air processes that accelerate filter degradation and pose health risks, leading to significant downtime and economic losses for trucking businesses.
Innovation Solution
A water-based cleaning machine that uses a soaking and rinsing process with low-pressure water and surfactants to effectively remove soot and contaminants from DPFs, minimizing damage and downtime, while recirculating water to conserve resources and reduce hazardous emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure air and high-temperature kiln baking are used for DPF cleaning, then cleaning effectiveness is improved, but cleaning time increases and filter damage occurs
Solution Approach 1:
The patent replaces the mechanical/thermal cleaning system (high-pressure air and kiln baking) with a chemical cleaning system using surfactant-based solutions. The chemical agents dissolve and emulsify soot and contaminants, enabling effective cleaning without prolonged exposure to extreme heat or high-pressure mechanical forces, thus reducing cleaning time while maintaining effectiveness.
Solution Approach 2:
The patent changes the cleaning parameters from extreme conditions (high temperature, high pressure) to moderate chemical conditions. By using surfactants and controlled chemical reactions, the cleaning process achieves effectiveness at lower temperatures and pressures, significantly reducing the cleaning cycle duration from hours to minutes while preventing filter damage.
2Reliability
If high-temperature kiln baking is used for DPF cleaning, then cleaning effectiveness is improved, but filter structure damage and adhesive degradation occur
Solution Approach 1:
The patent substitutes thermal-mechanical cleaning with chemical cleaning. The chemical surfactants penetrate and dissolve contaminants without subjecting the filter structure to extreme thermal stress that degrades adhesives and ceramic materials, thereby maintaining filter structural integrity while achieving effective cleaning.
Solution Approach 2:
The patent fundamentally changes the cleaning parameters from high-temperature thermal processing to moderate-temperature chemical processing. This parameter change eliminates the thermal degradation of adhesives and filter materials while maintaining cleaning effectiveness through chemical dissolution and emulsification of contaminants.
3Reliability
If traditional air/bake cleaning method is used, then cleaning is achieved, but health risks to employees and operational costs increase
Solution Approach 1:
The patent replaces the air/bake mechanical-thermal system with a chemical wet cleaning system. This substitution eliminates the generation of carcinogenic airborne ultra-fine DPM particles that pose health risks, while the contained liquid chemical process reduces operational costs by eliminating expensive personal protection equipment requirements and improving workplace safety compliance.
Solution Approach 2:
The patent converts the harmful dry combustion residues into a beneficial controlled chemical dissolution process. By using surfactants to emulsify and trap contaminants in liquid form, the process transforms potentially harmful airborne particles into contained, easily managed waste liquid that can be filtered and disposed of safely, eliminating health risks while maintaining cleaning capability.
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 machine achieves rapid, effective cleaning with minimal filter damage, enhanced workplace safety, and reduced operational costs by using a water-based soaking and rinsing process, allowing for quicker return to service and extending filter lifespan.
Implementation Method 1
A water-based cleaning machine that uses a soaking and rinsing process with low-pressure water and surfactants to effectively remove soot and contaminants from DPFs
Implementation Method 2
A water-based cleaning machine that uses a soaking and rinsing process with low-pressure water and surfactants to effectively remove soot and contaminants from DPFs
Implementation Method 3
A water-based cleaning machine that uses a soaking and rinsing process with low-pressure water and surfactants to effectively remove soot and contaminants from DPFs
Implementation Method 4
A water-based cleaning machine that uses a soaking and rinsing process with low-pressure water and surfactants to effectively remove soot and contaminants from DPFs
Data Source
AI summary
A diesel particulate filter cleaning machine. The filter is filed with a soaking solution comprising water and a surfactant and retained within the filter during a soaking interval. The filter is placed in a rinsing station after the soaking interval. A rinse water head positioned above an upper surface of the filter supplies rinse water into the filter, the rinse water passes through and drains from the filter. During the rinsing process, an actuator moves the rinse water head relative to the upper surface of the filter. A drain receives the rinse water after draining from the filter.