Engine Output Distribution for EGR Cooler Regeneration
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Solution Overview
Problem
Existing engine exhaust systems face challenges in efficiently regenerating particulate filters and exhaust gas recirculation (EGR) coolers due to difficulties in maintaining optimal exhaust temperatures, leading to increased fuel consumption and emissions, especially during varying engine loads and long trips.
Innovation Solution
A system and method that adjust engine load distribution among multiple vehicles in a consist to optimize exhaust temperatures for regeneration, by temporarily increasing the load on one engine and decreasing it on others, using a controller to manage throttle settings and maintain overall vehicle travel speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exhaust temperature is increased to regenerate particulate filters and EGR coolers, then regeneration effectiveness is improved, but fuel consumption increases
Solution Approach 1:
The system divides the vehicle fleet into multiple independently controllable vehicles, allowing selective regeneration of EGR coolers and particulate filters in specific vehicles while others continue normal operation. This segmentation enables distributed regeneration tasks that reduce overall fuel consumption compared to regenerating all vehicles simultaneously.
Solution Approach 2:
The system implements periodic regeneration cycles where vehicles alternate between regeneration mode and normal operation mode. By scheduling regeneration at optimal times and distributing it across the fleet over time, the system achieves effective regeneration while minimizing continuous fuel consumption increases.
2Reliability
If engine load is increased to raise exhaust temperature for regeneration, then regeneration capability is improved, but vehicle speed maintenance becomes difficult
Solution Approach 1:
The system segments the total vehicle fleet into regenerating vehicles and non-regenerating vehicles. By distributing the regeneration task across multiple vehicles rather than requiring all vehicles to increase load simultaneously, the system maintains overall fleet speed while enabling individual vehicles to achieve the exhaust temperatures needed for regeneration.
Solution Approach 2:
The system uses a controller as an intermediary that coordinates between vehicles, distributing regeneration tasks and adjusting engine loads in a way that maintains fleet-wide speed performance. The controller mediates the conflict between individual regeneration needs and collective speed maintenance by optimizing load distribution across the fleet.
3Use of energy by moving object
If regeneration is scheduled based on planned engine load settings, then fuel economy is improved, but planning accuracy decreases due to modeling errors and operating condition variations
Solution Approach 1:
The system incorporates sensors and controllers that continuously monitor actual exhaust temperatures, soot loading levels, and engine operating conditions. This feedback enables real-time adjustment of regeneration scheduling based on actual conditions rather than relying solely on pre-planned load settings, improving both fuel economy and planning accuracy despite modeling errors and variations.
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 enables efficient regeneration of particulate filters and EGR coolers, reducing fuel waste and emissions by optimizing exhaust temperatures while maintaining consistent vehicle performance.
Implementation Method 1
Under relatively high engine loads, exhaust temperature may be high enough to commence and sustain regeneration of the filter, during which soot accumulated on the filter burns and is thereby removed
Implementation Method 2
Some EGR systems include one or more EGR devices, such as coolers or mixers, to reduce the temperature of the exhaust to a desired temperature
Data Source
AI summary
Methods and systems for distributing engine output among vehicles of a consist are disclosed. One example system comprises a controller including non-transitory media having instructions stored on the media and executed by the controller for adjusting distribution of engine output between at least a first engine and a second engine in response to a regeneration mode, wherein the regeneration mode regenerates an exhaust gas recirculation (EGR) cooler that is coupled to the first engine.