DPF Heater Load Bank for DOC Exhaust Temperature Control

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Solution Overview

Problem

Existing systems fail to maintain a minimum exhaust temperature for diesel oxidation catalysts (DOC) and diesel particulate filters (DPF) in transport climate control systems, leading to potential engine deposits and inefficient engine operation.

Innovation Solution

Utilization of an electric heater or the like) to perform DPF regeneration for the prime mover is running. The DPF heater is used as a load bank to maintain a minimum exhaust temperature for the DOC by drawing additional load from the system, thereby preventing deposit formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the prime mover operates at low load, then fuel efficiency is improved, but exhaust temperature drops below the minimum required for DOC operation

Engineering Contradiction:

Improvefuel efficiencyVSAvoidexhaust temperature

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

An electric heater is introduced as an intermediary device to heat the exhaust gas when the prime mover operates at low load. The heater compensates for the insufficient exhaust temperature, allowing the DOC to function effectively while maintaining fuel-efficient operating conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system changes the temperature parameter of the exhaust gas by introducing external heating when needed. This allows the exhaust temperature to be maintained above the minimum threshold for DOC operation even when the prime mover operates at low load for fuel efficiency.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the DPF heater is used for regeneration only, then regeneration function is achieved, but exhaust temperature maintenance capability is underutilized

Engineering Contradiction:

ImproveDPF regenerationVSAvoidexhaust temperature maintenance

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The DPF heater is designed to perform multiple functions: it can conduct DPF regeneration when needed and simultaneously maintain exhaust temperature above the minimum threshold for DOC operation. This multi-functional use maximizes the utility of the heating system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses the existing DPF heater infrastructure to serve an additional purpose (exhaust temperature maintenance), rather than requiring a separate heating system. The heater serves itself by being controlled to maintain temperature during operation.

Inventive Principle:

Principle #25Self-service

3Reliability

If exhaust temperature is increased to prevent deposits, then DOC performance is improved, but additional energy consumption occurs

Engineering Contradiction:

ImproveDOC performanceVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system applies partial heating only when necessary to maintain the minimum exhaust temperature threshold for DOC operation, rather than continuously heating. This ensures adequate DOC performance while minimizing unnecessary energy consumption.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The control system monitors exhaust temperature and activates the heater only when the temperature drops below the minimum required threshold. This feedback-based control ensures DOC performance is maintained while avoiding excessive energy consumption during normal operation.

Inventive Principle:

Principle #23Feedback

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 DPF heater effectively maintains the required exhaust temperature, preventing deposit formation and ensuring optimal operation of the DOC and DPF, even when the prime mover is running.

Implementation Method 1

controlling a DPF heater used for regenerating a DPF... using the DPF heater as a load bank to maintain a minimum exhaust temperature

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the DPF heater as a load bank to raise the exhaust temperature... draw additional load from the system to drive up the exhaust temperature

Methodology Applied

Scientific EffectElectrical resistance heating: Joule Heating

Implementation Method 3

diesel oxidation catalyst (DOC)... maintain a minimum exhaust temperature for the DOC... preventing deposit formation

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentEP4234900B1Temperature control of an exhaust treatment system

Publication Date: 2025.12.24 THERMO KING CORP

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AI summary

Systems and methods for using a diesel particulate filter (DPF) heater as a load bank to maintain a minimum exhaust temperature for a diesel oxidation catalyst (DOC) paired with a prime mover are provided. The system includes a prime mover coupled with a generator, a compressor powered by the prime mover, a DOC disposed downstream from the prime mover, and a controller. The prime mover is separate from another prime mover used for operating a vehicle. The controller is configured to determine a load of the generator, to determine a load of the compressor, to determine a load of the prime mover based on the determined load of the generator and the determined load the compressor, and to control the load of the prime mover to maintain a minimum exhaust temperature for the DOC.