DPF Regeneration Control Using Parasitic Engine Load
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Solution Overview
Problem
Off-highway vehicles face challenges in effectively regenerating diesel particulate filters (DPF) due to insufficient operating temperatures, especially when engines idle or operate under conditions that prevent passive regeneration, leading to soot accumulation and reduced filter effectiveness.
Innovation Solution
A control system that induces a parasitic load on the engine by selectively increasing engine speed or hydraulic fluid pressure to raise the operating temperature of the DPF to at least 300°C, ensuring optimal regeneration conditions while minimizing fuel consumption and impact on machine operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive DPF regeneration is used, then the system is simpler and requires no additional energy input, but the operating temperature is insufficient to burn off accumulated soot during normal off-highway vehicle operation
Solution Approach 1:
The system changes the operating parameters of the engine by inducing a parasitic load, which increases engine speed and exhaust gas temperature. This temperature increase is specifically targeted to reach the 300°C threshold needed for DPF regeneration, while the control system manages energy consumption by only activating when necessary and limiting the parasitic load to less than 10% of maximum rated power output.
2Reliability
If periodic regeneration is performed, then the DPF is cleaned regularly, but regeneration occurs unnecessarily when soot accumulation is below acceptable levels
Solution Approach 1:
The control system incorporates a sensor that continuously monitors the fill state of the DPF and provides feedback to the controller. The controller compares the actual fill state against a threshold and only induces parasitic load when the fill state indicates regeneration is needed. This feedback mechanism prevents unnecessary regeneration events and optimizes fuel consumption by activating only when soot accumulation reaches levels requiring cleaning.
3Temperature
If engine speed is increased to raise operating temperature, then DPF regeneration is achieved, but machine productivity is reduced
Solution Approach 1:
The system uses periodic action by inducing parasitic load only during specific conditions when the vehicle is stationary or idle, rather than continuously. The control system monitors vehicle operation state and activates the parasitic load induction only when appropriate, minimizing impact on productivity while achieving the necessary temperature increase for regeneration. The parasitic load is removed when the vehicle requires full power operation.
4Temperature
If a hydraulic load valve is used to induce parasitic load, then the operating temperature reaches 300°C for regeneration, but the complexity of the hydraulic system increases
Solution Approach 1:
The hydraulic load valve serves multiple functions: it induces parasitic load for DPF regeneration, maintains hydraulic pressure during vehicle operation, and can be integrated with existing hydraulic circuitry. By designing the valve to work within the existing hydraulic system architecture and potentially serving dual purposes, the additional complexity is minimized while achieving the temperature increase needed for regeneration.
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 control system ensures successful DPF regeneration during natural machine operation, reducing soot accumulation and maintaining filter effectiveness without significantly impacting vehicle services or increasing fuel consumption.
Implementation Method 1
the controller is configured to selectively induce a parasitic load on the diesel engine to increase an operating temperature of the engine
Implementation Method 2
Through inducing the parasitic load on the engine, the engine load, and consequently the operating temperature of the engine, is raised so as to become more favorable to regenerating the DPF
Implementation Method 3
The hydraulic load valve may be configured to increase hydraulic fluid pressure along the hydraulic circuit to induce the parasitic load onto the hydraulic system
Implementation Method 4
Passive DPF filters use a catalyst to remove accumulations
Implementation Method 5
the soot collected on the DPF can be burned off, which is known as regeneration of the DPF
Data Source
AI summary
A control system is provided for a diesel particulate filter (DPF) system of a diesel engine configured for operation in an off-highway vehicle. The control system includes a controller configured to receive a signal corresponding to a fill state of the DPF being at or above a first threshold. The controller is configured to selectively induce a parasitic load on the diesel engine to increase an operating temperature of the engine in response to receiving the signal.