Diesel Particulate Filter Regeneration Using Generator Power
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Solution Overview
Problem
Diesel engines with mechanical injection pumps face challenges in self-regenerating diesel particulate filters due to inability to electronically control fuel injection, leading to clogged filters, increased operational costs, and limited power generation capacity, especially in continuous use applications like submersible pumps.
Innovation Solution
An exhaust gas combustion device with a heater and pressure sensors controlled by a controller to heat exhaust gas and combust particulate matter, using power from the power generating unit to maintain continuous operation without stopping the engine, and allowing for a larger capacity heater to efficiently regenerate filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal regeneration is performed using a dedicated filter regeneration mechanism or external power supply, then PM removal from DPF is achieved, but the operation time and operation area of the machine are limited
Solution Approach 1:
The system uses the power generating unit's own generated power to operate the heater for DPF regeneration, eliminating the need for external power supply or dedicated regeneration mechanisms. The power generating unit serves both its primary function of generating electricity and the secondary function of providing power for filter regeneration, thereby extending operation time and area without additional equipment.
2Reliability
If a small-capacity power generator is used for thermal regeneration, then the machine can be equipped with regeneration capability, but the margins of space and engine output are limited
Solution Approach 1:
The power generating unit is designed to perform multiple functions: generating electricity for the load and providing power for DPF regeneration. By making the power generating unit universal, the system eliminates the need for separate regeneration equipment, thereby maintaining full engine output and space margins while achieving reliable PM removal capability.
3Productivity
If multiple DPFs are disposed in parallel for continuous operation, then the machine can operate without stopping, but the whole machine becomes larger
Solution Approach 1:
Instead of using multiple DPFs in parallel, the system uses a single DPF that can be regenerated in-place using the power generating unit's own power. This self-service approach allows continuous operation without requiring additional filter components, thereby maintaining compact machine size while achieving continuous productivity.
4Reliability
If the diesel engine stops for DPF regeneration, then PM can be combusted and removed, but the machine cannot be used continuously over long periods
Solution Approach 1:
The system enables continuous regeneration operation by using the power generating unit's power to operate the heater without stopping the diesel engine. This maintains continuous useful action - the engine keeps running while PM is combusted and removed from the DPF, eliminating the need to stop for regeneration and thereby extending continuous use duration while maintaining reliable PM removal.
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
Enables continuous operation of diesel engines by efficiently regenerating diesel particulate filters without stopping the engine, reducing maintenance needs, and allowing for higher power generation capacity by using the engine's power to heat and combust particulate matter, thus preventing filter clogging and enhancing PM removal.
Implementation Method 1
a heater which heats the exhaust gas before introduced into the collector
Implementation Method 2
exhaust gas to be introduced into the DPF is constantly maintained at a high temperature, and fuel injected into the exhaust gas by post injection is combusted with the catalyst, whereby PM adhering to the DPF is combusted
Data Source
AI summary
Provided is an exhaust gas combustion device which is capable of early prevention of clogging, and also a power generator including the device. An exhaust gas combustion device of the present invention includes: a DPF; a sensor which measures the pressure of exhaust gas to be introduced into the DPF; a sensor which measures the pressure of exhaust gas purified by the DPF; and a controller which receives outputs from both sensors and calculates a pressure difference. When the pressure difference is equal to or larger than a preset threshold, the heater is supplied with power from a power generating unit to thereby heat exhaust gas. Accordingly, PM accumulated inside the DPF is combusted and removed, preventing excessive clogging of the DPF even during light-load operation.