Electric Heating Device for Exhaust System Catalyst Activation
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Solution Overview
Problem
Existing exhaust systems face challenges in quickly achieving the required temperature for catalyst activation downstream of internal combustion engines, especially in locations remote from the engine, leading to inefficiencies and increased complexity due to tightening emission regulations and the need for precise pollutant conversion.
Innovation Solution
A method using an electric heating device with a temperature model-based control system to determine and provide the precise amount of heat required, minimizing energy consumption and preventing overheating by calculating heating power based on physical parameters and dynamically adjusting the heating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electric heating devices are used to heat exhaust system components, then the heating speed and temperature control are improved, but the energy consumption increases
Solution Approach 1:
The control unit activates the electric heating device before the exhaust system components reach their operating temperature threshold. By anticipating the heating need and applying heat proactively, the system ensures rapid temperature achievement while avoiding unnecessary prolonged heating, thus optimizing energy consumption.
Solution Approach 2:
The control unit continuously monitors the temperature of exhaust system components and dynamically adjusts the heating power of the electric heating device based on real-time temperature feedback. This closed-loop control prevents overheating and minimizes energy consumption by matching heating output to actual temperature requirements.
2Reliability
If multiple catalysts are installed in series to meet emission limits, then the pollutant conversion efficiency is improved, but the system complexity increases
Solution Approach 1:
The electric heating device serves multiple functions: it heats all catalyst components in series to their respective operating temperatures, maintains optimal temperatures during transient conditions, and prevents overheating. This single multi-functional heating system replaces what would otherwise require multiple separate heating devices for each catalyst, thereby reducing overall system complexity while ensuring all components achieve their required conversion efficiencies.
3Temperature
If internal engine heating measures are used, then the catalyst heating is achieved, but the engine efficiency deteriorates
Solution Approach 1:
The patent replaces the mechanical/internal engine heating method (which requires late ignition angles and increased exhaust gas temperature) with an electrical heating system. The electric heating device directly heats the catalyst components using electrical energy from the vehicle's electrical system, independent of engine operating conditions. This substitution eliminates the trade-off between catalyst heating and engine efficiency, as the electrical heating system can operate without compromising combustion optimization.
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 allows for efficient and rapid heating of the exhaust system components, optimizing energy use and protecting critical components from overheating, while ensuring precise temperature control and adaptation to varying operating conditions.
Implementation Method 1
heating an exhaust system downstream of an internal combustion engine by means of an electric heating device
Implementation Method 2
A method using an electric heating device with a temperature model-based control system to determine and provide the precise amount of heat required
Data Source
AI summary
A method (200) for heating an exhaust system (120) downstream of an internal combustion engine (1) by means of an electric heating device (14, 15). In one example, the method includes determining a current temperature (t_EHC, t_EHC{circumflex over ( )}Us, t_Cat) in the exhaust system (120), determining a heating demand (t_EHC{circumflex over ( )}Des) based on the determined current temperature (t_Cat) and a target temperature, calculating a required amount of heat (Pwr{circumflex over ( )}Des) on the basis of the heating demand and an amount of energy required to heat the electric heating device (14, 15), and controlling (Pwr{circumflex over ( )}Req) the electric heating device (14, 15) to generate the calculated amount of heat.