Dual Path Exhaust Temperature Control for Emissions Simulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Real internal combustion engines are inconsistent, maintenance-intensive, and expensive for long-term emissions testing, and they do not allow for the separate evaluation of individual variables like fuel and oil effects.

Innovation Solution

A burner-based exhaust flow simulation system with a dual path temperature control section, which includes a heat exchanger and oil injection system, simulates engine exhaust conditions, allowing precise temperature control and separate evaluation of fuel and oil effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a real internal combustion engine is used for long term emissions testing, then the testing can be performed with actual engine conditions, but the system becomes maintenance intensive, expensive to operate, and inconsistent

Engineering Contradiction:

Improvetesting consistencyVSAvoidsystem maintenance requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a simplified copy of the engine exhaust system that replicates the thermal and compositional characteristics of real engine exhaust without requiring an actual running engine. The test cell uses controlled combustion chambers and exhaust gas recirculation to simulate engine exhaust conditions, eliminating the need for maintenance-intensive real engines while maintaining testing realism

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The system replaces expensive, maintenance-intensive real engines with a more economical simulated exhaust generation system. The simulation apparatus uses simpler combustion control mechanisms and gas recirculation components that are less costly to operate and maintain over long testing periods

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Adaptability or versatility

If a real engine is used for testing, then actual exhaust conditions are produced, but separate evaluation of individual variables such as fuel and oil effects is not permitted

Engineering Contradiction:

Improvevariable evaluation capabilityVSAvoidtesting system flexibility

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The simulated exhaust system divides the exhaust generation into separate controllable components: fuel combustion chambers, oil injection systems, and exhaust gas recirculation pathways. This segmentation allows independent control and evaluation of fuel effects, oil effects, and other variables by adjusting individual components while keeping others constant

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system employs dynamic control mechanisms including variable fuel flow rates, adjustable oil injection quantities, and controllable exhaust gas recirculation ratios. These dynamic adjustments enable systematic variation of individual parameters to evaluate their separate effects on emissions control devices

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If a burner-based exhaust gas simulation system is used, then consistent and cost-effective testing is achieved, but the exhaust temperature becomes elevated (1000 degrees or more) and requires precise control

Engineering Contradiction:

Improvetemperature control precisionVSAvoidexhaust gas temperature

Core Design Contradiction:

Manufacturing precisionVSTemperature

Solution Approach 1:

The patent introduces an intermediary cooling system between the high-temperature burner and the test subject. This includes heat exchangers and temperature control apparatus that mediate the thermal energy, reducing the exhaust temperature from 1000+ degrees to the desired test range while maintaining the simulated exhaust composition and flow characteristics

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system dynamically adjusts temperature parameters through controlled cooling mechanisms and exhaust gas recirculation. By varying the recirculation ratio and cooling intensity, the system maintains precise temperature control at the test subject while the burner operates at high temperatures for efficient exhaust generation

Inventive Principle:

Principle #35Parameter changes

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 consistent and cost-effective simulation of engine exhaust conditions, allowing for the evaluation of emissions control devices and other components under various conditions, including the effects of additives and contaminants.

Implementation Method 1

a heat exchanger downstream the burner is used for temperature control

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS7578179B2Exhaust gas simulation system with dual path temperature control for control of exhaust temperature

Publication Date: 2009.08.25 SOUTHWEST RES INST

AI summary

A temperature control system and method for use with an exhaust flow simulation system. A typical exhaust flow simulator is a burner-based system, in which exhaust from a combustive burner is exhausted through an exhaust line. A temperature control section divides the exhaust from the burner line into two paths: a cool path and an uncooled (hot) path. The cool path uses a heat exchanger to cool the exhaust. The cool path also has a control valve that controls the relative portions of hot and cool exhaust, which are re-mixed downstream the valve into an exhaust line. Various embodiments have different configurations for the two paths.