Three-Tiered DPF Cleaning Control for Working Machines
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Solution Overview
Problem
Existing working machines with diesel particulate filters (DPFs) face challenges in efficiently managing particulate matter (PM) accumulation, as current cleaning methods lack a comprehensive approach to handle PM deposits between threshold levels, leading to inefficient maintenance and potential oil dilution due to frequent filter cleaning.
Innovation Solution
The implementation of a three-tiered cleaning system: automatic cleaning for high PM deposits, manual cleaning for higher thresholds, and assist cleaning for intermediate levels, utilizing a combination of automatic and manual switch controls to manage PM deposits effectively, preventing frequent filter cleaning and oil dilution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automatic cleaning is performed when PM deposits reach the first threshold, then filter cleaning is automated and operator intervention is reduced, but frequent cleaning may cause oil dilution and increased maintenance complexity
Solution Approach 1:
The cleaning system is segmented into three distinct operational modes: automatic cleaning for high PM deposits (first threshold or more), manual cleaning for intermediate deposits (between first and second thresholds), and assist cleaning for low PM deposits (below first threshold). This segmentation allows each mode to operate under specific conditions, preventing unnecessary frequent cleaning that would cause oil dilution while maintaining automation where beneficial.
Solution Approach 2:
The system continuously monitors PM deposits amount and provides feedback to the controller, which automatically selects the appropriate cleaning mode based on the current deposit level. This feedback mechanism ensures that cleaning operations are triggered only when necessary, preventing oil dilution from excessive or premature cleaning while maintaining efficient automation.
2Ease of operation
If manual cleaning is required for intermediate PM levels, then operator control is maintained for precise cleaning, but maintenance frequency and operational complexity increase
Solution Approach 1:
The cleaning control system is segmented into three distinct operational modes: automatic cleaning for high PM deposits (first threshold or more), manual cleaning for intermediate deposits (between first and second thresholds), and assist cleaning for low PM deposits (below first threshold). This segmentation allows each mode to operate under specific conditions, maintaining operator control for intermediate levels while automating extreme cases.
Solution Approach 2:
The system uses parameter changes in PM deposits amount to automatically transition between different cleaning modes. When deposits fall within the intermediate range (between first and second thresholds), the system enables manual cleaning mode, giving operators control precision for these moderate cases while maintaining automated monitoring and control for extreme conditions.
3Reliability
If filter cleaning is performed frequently to maintain filter efficiency, then PM management is proactive, but oil dilution occurs and maintenance costs increase
Solution Approach 1:
The system performs preliminary monitoring of PM deposits and only initiates cleaning operations when deposits reach specific thresholds. This preliminary action approach ensures that cleaning is performed proactively to maintain filter efficiency while avoiding unnecessary frequent cleaning that would cause oil dilution. The three-tiered threshold system ensures cleaning occurs only when truly needed.
Solution Approach 2:
The system uses parameter changes in PM deposits amount to determine optimal cleaning timing. By monitoring deposits and triggering cleaning only when they reach the first threshold (automatic), fall between thresholds (manual), or drop below (assist), the system maintains filter efficiency proactively while preventing oil dilution from excessive or premature cleaning operations.
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 system ensures efficient PM management by performing assist cleaning after automatic cleaning has stopped, preventing oil dilution and allowing for easy distinction between assist and manual cleaning operations, thereby maintaining filter efficiency and reducing maintenance frequency.
Implementation Method 1
a filter (41) that catches the particulate matters (PM) included in exhaust gas that is exhausted from a prime mover (E1)
Implementation Method 2
perform automatic cleaning that automatically combusts the particulate matters
Implementation Method 3
combusts the particulate matters caught by the filter
Data Source
AI summary
A working machine includes a manual switch, a filter to catch particulate matters included in exhaust gas that is exhausted from a prime mover, a first cleaning controller to perform automatic cleaning that automatically combusts the particulate matters when a deposits amount of the particulate matters caught by the filter is a first deposits amount threshold or more, a second cleaning controller to perform manual cleaning that combusts the particulate matters based on a command of the manual switch when the deposits amount is equal to or more than a second deposits amount threshold that is larger than the first deposits amount threshold, and a third cleaning controller to perform assist cleaning that combusts the particulate matters based on the command of the manual switch when the deposits amount is equal to or more than the first deposits amount threshold and smaller than the second deposits amount threshold.