Common Rail DPF Regeneration Control
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Solution Overview
Problem
Conventional exhaust gas purification systems for engines, such as those in construction machines, experience increased fuel consumption and uncomfortable operator feedback due to sudden shocks and engine sound changes during diesel particulate filter (DPF) regeneration, which can be misinterpreted as abnormalities.
Innovation Solution
An exhaust gas purification system for common rail type engines that includes multiple renewal modes, including an initialization mode for post-injection fuel supply regardless of clogged states, along with notification and operational controls to manage DPF regeneration, ensuring efficient particulate matter burning without operator intervention and minimizing fuel consumption and engine durability issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If DPF regeneration is performed by enhancing exhaust gas temperature in conventional systems, then particulate matter is effectively removed, but fuel consumption increases excessively and causes sudden engine torque fluctuations that create shocks and uncomfortable operator feedback
Solution Approach 1:
The system performs preliminary detection of PM accumulation level and proactively initiates regeneration before the DPF becomes fully clogged. By using a PM detection device to monitor particulate matter levels and comparing them against threshold values, the system schedules regeneration at optimal moments, preventing excessive accumulation that would require more intensive (and fuel-consuming) regeneration later. This preliminary action reduces the overall energy required for regeneration cycles.
Solution Approach 2:
The system implements a feedback mechanism where the PM detection device continuously monitors particulate matter levels in the DPF, and this information feeds back to the control unit which adjusts regeneration timing and intensity accordingly. The control unit receives feedback from both the PM detection device and differential pressure detection device, and uses this feedback to determine the optimal regeneration moment, thereby optimizing fuel consumption while ensuring effective PM removal.
2Reliability
If DPF regeneration is performed by enhancing exhaust gas temperature in conventional systems, then particulate matter is effectively removed, but sudden engine torque fluctuations occur causing shocks and changes in engine sound that create uncomfortable operator feedback
Solution Approach 1:
The system performs preliminary detection of PM accumulation level and proactively initiates regeneration before the DPF becomes fully clogged. By using a PM detection device to monitor particulate matter levels and comparing them against threshold values, the system schedules regeneration at optimal moments, preventing excessive accumulation that would require more intensive (and disruptive) regeneration later. This preliminary action reduces the severity of torque fluctuations and associated operator discomfort.
Solution Approach 2:
The system implements a feedback mechanism where the PM detection device continuously monitors particulate matter levels in the DPF, and this information feeds back to the control unit which adjusts regeneration timing and intensity accordingly. The control unit receives feedback from both the PM detection device and differential pressure detection device, and uses this feedback to determine the optimal regeneration moment, thereby minimizing sudden torque fluctuations and associated operator discomfort.
3Adaptability or versatility
If multiple renewing modes are implemented with initialization mode for post-injection, then DPF regeneration can be executed regardless of clogged state, but system complexity increases with multiple control modes and detection requirements
Solution Approach 1:
The system segments the DPF regeneration process into distinct modes (normal renewal mode and initialization renewal mode) with clearly defined entry and exit conditions. Each mode has specific control logic and parameter settings, allowing the system to handle different DPF states appropriately. The segmentation is implemented through a state machine approach in the control unit, which transitions between modes based on detection results from PM and differential pressure sensors, thereby managing complexity through structured organization.
Solution Approach 2:
The control unit is designed with multi-functionality to handle both normal renewal operations and initialization renewal operations within a single integrated system. The same control unit processes inputs from both PM detection device and differential pressure detection device, determines appropriate regeneration timing, and executes fuel injection control. This universal design reduces overall system complexity compared to having separate dedicated systems for each function.
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 system efficiently regenerates the DPF without operator setting, reduces fuel consumption, and prevents excessive particulate matter deposition, thereby smoothing engine operation and avoiding uncomfortable operator feedback.
Implementation Method 1
a diesel particulate oxidizer disposed in an exhaust system of the diesel engine and having a trap carrier for collecting unburnt fine particles contained in exhaust gas, said trap carrier supporting an oxidation catalyst; a regeneration means for burning the unburnt fine particles collected in said diesel particulate oxidizer
Implementation Method 2
a regeneration means for burning the unburnt fine particles collected in said diesel particulate oxidizer
Data Source
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AI summary
It is an object of the present invention to improve a fuel consumption and avoid an engine oil dilution compatible, at a time of renewal of an exhaust gas purification device 50. An exhaust gas purification system of the present invention is provided with the exhaust gas purification device 50 which is arranged in an exhaust gas route 77 of a common rail type engine 70, and is structured such that a plurality of renewing modes which burn and remove a particulate matter deposited within the exhaust gas purification device 50 is executed. One of the plurality of renewing modes is an initialization renewing (a forced renewing) mode which supplies a fuel into the exhaust gas purification device 50 by a post injection E regardless of a clogged state of the exhaust gas purification device 50, in the case that an accumulated drive time Te of the engine 70 becomes equal to or more than a previously set time T0.