Diesel Particulate Filter Cleaning with Opposing Nozzle Arrays
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Solution Overview
Problem
Current methods for cleaning diesel particulate filters are inefficient, labor-intensive, and often fail to remove a significant portion of accumulated particulate matter, leading to reduced filter lifespan and increased maintenance frequency, with limitations in accommodating different filter sizes and shapes, and inability to effectively identify damaged filters.
Innovation Solution
A method and apparatus using pressurized air directed from both ends of the filter, with movable nozzle members and a rotating turntable to dislodge and remove particulate material, allowing for visual observation of the cleaning process and identification of damage, and adjustable components to accommodate various filter sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cleaning with compressed air hose is used, then labor intensity is reduced, but cleaning effectiveness deteriorates and significant particulate matter remains in the filter
Solution Approach 1:
The filter end face is divided into multiple zones with multiple nozzles arranged in arrays, allowing simultaneous cleaning of different regions. The nozzles are segmented into first and second arrays on opposite sides of the filter, enabling comprehensive coverage without requiring manual repositioning of a single hose.
Solution Approach 2:
The nozzle arrays are made movable along the filter end faces, allowing dynamic adjustment to accommodate different filter sizes and shapes. This mechanical mobility enables the system to adapt to various geometries while maintaining automated operation, resolving the contradiction between ease of operation and cleaning effectiveness.
2Productivity
If frequent cleaning is performed to maintain filter performance, then engine efficiency is preserved, but filter lifespan is reduced due to excessive handling
Solution Approach 1:
Manual handling operations are replaced with an automated mechanical system that cleans the filter in place. The movable nozzle arrays eliminate the need for operators to manually manipulate the filter, thereby preserving filter lifespan through reduced handling while maintaining cleaning frequency for engine efficiency.
Solution Approach 2:
The system enables self-service cleaning where the filter is cleaned without being removed from its mounting position. The movable nozzles access the filter ends in place, allowing the filter to service itself through automated cleaning rather than requiring manual removal and handling.
3Device complexity
If existing cleaning equipment is used, then cleaning process is simplified, but ability to accommodate different filter sizes and shapes is limited
Solution Approach 1:
The cleaning system is designed with universal applicability through movable nozzle arrays that can be positioned to accommodate various filter geometries. The same basic apparatus can clean different sizes and shapes of filters by adjusting the nozzle positions, providing multi-functionality without requiring multiple specialized devices.
Solution Approach 2:
The movable nozzle arrays provide dynamic adaptability to different filter configurations. The mechanical mobility allows the system to adjust its geometry to match various filter sizes and shapes, resolving the contradiction between process simplicity and versatility.
4Device complexity
If traditional cleaning methods are used, then equipment simplicity is maintained, but ability to identify damaged filters is lost
Solution Approach 1:
The system incorporates visual feedback mechanisms that allow operators to observe the cleaning process and identify damaged filters. By watching particulate matter discharge patterns during automated cleaning, operators can detect damaged cells or broken media without adding complex diagnostic equipment, maintaining simplicity while enabling damage identification.
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 significantly increases the efficiency of particulate removal, extends filter lifespan, allows for rapid identification of damaged filters, and facilitates convenient cleaning of diverse filter sizes and shapes, reducing manual labor and maintenance frequency.
Implementation Method 1
directing a flow of compressed air from a first nozzle member into the axially-extending filter cells from a first end face of the diesel particulate filter; simultaneously directing a flow of compressed air from a second nozzle member into the axially-extending filter cells from a second, opposite end face of the diesel particulate filter
Data Source
Figure 1
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Figure 4
AI summary
An apparatus for pneumatic cleaning of diesel particulate filters (DPF). First and second nozzle members direct flows of compressed air into the axially-extending filter cells from both ends of the filter, the nozzle members generally being offset so as to avoid blowing directly towards one another. The flows form the nozzles impinge only relatively small areas of the end faces of the filter media, e.g., only one or a few cells at a time. The nozzle members are moved over substantially the entirety of the first and second end faces, so that as cleaning progresses compressed air is directed into substantially all of the filter cells from opposite directions. The nozzles may be translated on reciprocated arms while the filter is rotated simultaneously on a turntable or rollers, so that the nozzles sweep over the whole surface of each end; other mechanisms, such as various combinations of gears or pistons, may be used for relative movement between the nozzles and filters. Also, the nozzle members may have single or multiple nozzles. The filter and nozzles are housed within a cabinet having one or more windows therein, which enable an operator to view progress of the cleaning process and determine when it is complete. Visual observation and also enables an operator to identify filters having damaged media, as indicated by particulate material billowing from both ends of the filter due to cracked or broke axial cells. The dislodged particulate material is withdrawn from the cabinet by an exhaust duct system.