Diesel Particulate Filter Regeneration via Trip Plan Optimization
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Solution Overview
Problem
Conventional diesel particulate filters become backlogged with particulate matter, leading to poor diesel exhaust gas flow and inefficient engine operation, as existing systems lack efficient methods for removing trapped particulate matter.
Innovation Solution
A system and method that includes sensors to monitor particulate matter levels, an engine controller, and a locomotive controller to create a trip plan optimizing power settings along a route, with the engine controller increasing the temperature of diesel exhaust gas entering the particulate filter during predetermined time or distance regions to oxidize and remove trapped particulate matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diesel particulate filter operates for a prolonged period, then it captures sufficient particulate matter to restrict exhaust flow, but the filter becomes backlogged and requires maintenance
Solution Approach 1:
The system performs preliminary regeneration actions before the filter becomes completely backlogged. By continuously monitoring exhaust flow and particulate levels, the system initiates regeneration cycles at optimal times to prevent complete blockage, thereby extending maintenance intervals while ensuring reliable exhaust flow.
Solution Approach 2:
The system uses feedback from sensors monitoring exhaust flow rate and particulate matter levels to dynamically control regeneration cycles. This feedback mechanism allows the system to adjust regeneration timing and duration based on actual filter loading conditions, optimizing the balance between exhaust flow reliability and maintenance frequency.
2Productivity
If regeneration is performed to remove trapped particulate matter, then exhaust flow improves, but energy is consumed during the regeneration process
Solution Approach 1:
The system performs regeneration periodically rather than continuously, using short intermittent cycles that oxidize particulate matter without sustained high energy input. By timing regeneration cycles to coincide with periods of high engine power output, the system minimizes energy consumption while maintaining effective particulate removal and exhaust flow.
Solution Approach 2:
The system changes operating parameters such as engine power setting and exhaust temperature during regeneration cycles. By coordinating regeneration with high-power engine operating conditions, the system utilizes existing thermal energy and power output to facilitate particulate oxidation, thereby reducing additional energy consumption while maintaining high exhaust flow rates.
3Power
If the engine operates at high power settings, then more energy is available for regeneration, but the locomotive may not be able to maintain optimal power output
Solution Approach 1:
The system dynamically adjusts engine power settings during regeneration cycles based on real-time conditions. By modulating power output to provide just enough energy for effective regeneration while maintaining locomotive efficiency, the system optimizes the balance between power availability for particulate removal and overall locomotive productivity.
Solution Approach 2:
The system maintains continuous useful action by coordinating regeneration cycles with productive engine operating periods. Rather than stopping engine operation for regeneration, the system performs particulate removal during high-power segments of the trip plan, ensuring that engine power is continuously utilized for both propulsion and regeneration purposes.
4Object-generated harmful factors
If conventional regeneration techniques are used, then particulate matter is removed, but the process is inefficient and causes poor engine operation
Solution Approach 1:
The system replaces conventional mechanical regeneration methods with a controlled oxidation process. By using oxygen from the exhaust stream and coordinating thermal oxidation with engine power output, the system efficiently removes particulate matter through chemical oxidation rather than mechanical means, thereby improving engine operation efficiency while effectively eliminating trapped particulate matter.
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 effectively removes trapped particulate matter, improving diesel engine efficiency and minimizing energy loss by optimizing regeneration processes based on real-time data and power settings, thereby maintaining optimal engine performance.
Implementation Method 1
increasing the temperature of the particulate filter, causing the soot particles to oxidize and burn off of the particulate filter
Implementation Method 2
The engine controller is configured to increase the temperature of the diesel exhaust gas entering the diesel particulate filter
Data Source
AI summary
A system (410") is provided for removing particulate matter from a diesel particulate filter (414"). The system includes an engine controller (429") coupled to a diesel engine (411"), and to a locomotive controller (444").The locomotive controller ' includes an algorithm /program to create a trip plan to optimize the performance of the locomotive (441") along a route in accordance with a power setting of the diesel engine at each location along the route. Sensors (420 ",422") are configured to output a first alert signal to the engine controller once the trapped particulate matter exceeds a predetermined threshold. Upon receiving the first alert signal the engine controller communicates with the locomotive controller to determine a time region or distance region within the trip plan when the power setting exceeds a power threshold. The engine controller increases the temperature of the diesel exhaust gas entering the diesel particulate filter during the time region or distance region.