DPF Emergency Regeneration via Pressure Differential Feedback
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Solution Overview
Problem
Existing exhaust emission purification systems face challenges in ensuring reliable forced regeneration of diesel particulate filters (DPFs) during emergency conditions, leading to potential filter clogging due to inadequate manual regeneration processes, which burden drivers and may result in incomplete purification.
Innovation Solution
An exhaust emission purification method and system that issues an alarm for manual regeneration and automatically performs forced regeneration under predetermined conditions, such as insufficient purification, expired regeneration time, or excessive pressure difference, ensuring reliable regeneration even without driver input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual regeneration is performed only when driver receives alarm, then driver burden is reduced, but regeneration reliability deteriorates due to potential driver inaction
Solution Approach 1:
The system enables automatic regeneration mode where the exhaust emission purification device performs forced regeneration automatically without requiring driver intervention. The control unit detects regeneration needs based on pressure differential sensors and automatically executes multi-injection or post-injection to raise exhaust temperature and burn accumulated PM, making the system self-servicing and eliminating driver burden while ensuring regeneration reliability.
Solution Approach 2:
The system uses pressure differential sensors to continuously monitor the state of the DPF and provides feedback to the control unit. When the pressure differential exceeds predetermined thresholds, the control unit receives this feedback and automatically initiates forced regeneration, creating a closed-loop control system that ensures regeneration occurs reliably without driver intervention.
2Reliability
If forced regeneration is performed frequently, then PM removal is ensured, but fuel consumption increases due to multi-injection and post-injection
Solution Approach 1:
The system changes operational parameters by using pressure differential thresholds to determine regeneration timing. Instead of frequent scheduled regenerations, the system monitors actual DPF loading conditions through pressure sensors and only performs forced regeneration when pressure differential exceeds predetermined thresholds, optimizing the balance between PM removal and fuel consumption.
Solution Approach 2:
The system applies partial action by using multi-injection or post-injection only when and where needed - specifically when pressure differential indicates PM accumulation requires removal. The injection strategy is adjusted based on actual conditions rather than applying full injection continuously, reducing unnecessary fuel consumption while ensuring PM removal when required.
3Productivity
If DPF clogging is allowed to progress, then filter capacity is utilized fully, but exhaust gas pressure increases reducing engine performance
Solution Approach 1:
The system performs preliminary action by monitoring pressure differential continuously and executing forced regeneration before the DPF becomes fully clogged. When the pressure differential reaches predetermined thresholds indicating significant PM accumulation, the control unit proactively initiates multi-injection or post-injection to raise exhaust temperature and burn PM, preventing complete clogging and maintaining exhaust flow and engine performance.
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 reduces the burden on drivers by ensuring reliable forced regeneration, preventing filter clogging and maintaining system efficiency by automatically initiating regeneration when necessary conditions are met.
Implementation Method 1
hydrocarbon (HC), supplied in the exhaust gas by post-injection or the like, burns at the oxidation catalyst installed on the upstream side of the filter or the oxidation catalyst supported on the filter. With this, the temperature of the exhaust gas is raised at the inlet or on the surface of the filter by utilizing oxidative reaction heat.
Implementation Method 2
a continuous purification type DPF device as one of exhaust gas purification devices which collect particulate matter (hereinafter, PM) discharged from diesel engines by a filter
Implementation Method 3
the PM collected by the DPF is continuously burned and purified and thereby the DPF will self-regenerate, while the exhaust gas temperature is approximately 350 °C or greater
Implementation Method 4
the temperature of the exhaust gas is raised at the inlet or on the surface of the filter by utilizing oxidative reaction heat. The exhaust gas raises the temperature of the filter exceeding a temperature at which the PM accumulated on the filter is burned and thus the PM is removed.
Data Source
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AI summary
In case of emergency regeneration, i.e. any one of forced regeneration after a judgment is made that purification is insufficient in purification judgment after ending forced regeneration, forced regeneration after time has expired before completing of forced regeneration, or forced regeneration when the pressure difference across a DPF exceeds a predetermined first judging pressure difference under a state where traveling distance of a vehicle is shorter than a predetermined distance for judgment an alarm for urging manual regeneration is issued, and wherein when manual regeneration is designated thereafter manual regeneration is performed and when predetermined conditions are satisfied without the reception of a designation of manual regeneration, automatic regeneration is performed. In forced regeneration of the DPF for purifying PM in exhaust gas, forced regeneration is performed surely even if manual regeneration is not selected at the time of emergency regeneration, and convenience is enhanced by reducing burden on a driver.