Engine Torque Control for Exhaust Regeneration
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Solution Overview
Problem
At low torque output and environmental temperatures, the exhaust temperature of exhaust gas flow may fall below the threshold required for particulate filter regeneration in machines like wheel loaders, and insufficient fuel in the exhaust gas can lead to hydrocarbon build-up in the aftertreatment module, hindering efficient operation.
Innovation Solution
A system with a controller that determines the actual exhaust temperature and minimum fuel amount, compares it to a threshold, and adjusts the engine torque using a parasitic load to attain a target torque output, ensuring sufficient temperature and fuel for effective regeneration of the particulate filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the engine operates at low torque output, then fuel consumption is reduced, but exhaust temperature falls below the threshold required for particulate filter regeneration
Solution Approach 1:
The controller proactively monitors exhaust temperature and compares it with the regeneration threshold before regeneration can fail. When the threshold is approached, the controller preemptively increases fuel injection amount to raise exhaust temperature, preventing the temperature from falling below the required level for particulate filter regeneration.
Solution Approach 2:
The system dynamically adjusts the fuel injection amount parameter based on real-time exhaust temperature measurements. By changing the fuel injection parameter, the system can control exhaust temperature to maintain it above the regeneration threshold, thereby resolving the contradiction between low fuel consumption and sufficient exhaust temperature for regeneration.
2Productivity
If the engine operates at low torque output, then productivity is reduced, but exhaust temperature remains insufficient for regeneration
Solution Approach 1:
The system changes the fuel injection amount parameter to control exhaust temperature independently of torque output. This allows the engine to operate at low torque for high productivity while simultaneously adjusting fuel injection to maintain exhaust temperature above the regeneration threshold.
Solution Approach 2:
The controller uses feedback from exhaust temperature sensors to continuously monitor and adjust fuel injection amount. This closed-loop control ensures that exhaust temperature remains sufficient for regeneration even when torque output is low, decoupling the relationship between productivity and regeneration capability.
3Use of energy by moving object
If fuel injection amount is reduced to save fuel, then fuel consumption decreases, but hydrocarbon build-up occurs in the aftertreatment module
Solution Approach 1:
The controller implements feedback control by monitoring exhaust temperature and adjusting fuel injection amount accordingly. This ensures that the minimum fuel amount required for complete combustion and prevention of hydrocarbon build-up is maintained, while still optimizing overall fuel consumption by avoiding excessive fuel injection.
Solution Approach 2:
The system dynamically adjusts the fuel injection parameter to maintain optimal combustion conditions. By changing the fuel injection amount based on real-time conditions, the system prevents hydrocarbon build-up in the aftertreatment module while minimizing fuel consumption through precise control.
4Reliability
If fuel injection amount is increased to raise exhaust temperature, then regeneration capability is improved, but fuel consumption increases
Solution Approach 1:
The system optimizes the fuel injection parameter by adjusting it only to the extent necessary to maintain exhaust temperature above the regeneration threshold. This precise parameter control ensures reliable regeneration capability while minimizing the additional fuel consumption required to achieve it.
Solution Approach 2:
The feedback control system monitors exhaust temperature and adjusts fuel injection amount to the minimum level required for regeneration. This prevents excessive fuel injection while ensuring that regeneration capability is maintained, thereby optimizing the trade-off between reliability and fuel consumption.
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 ensures efficient regeneration of the particulate filter by maintaining adequate exhaust temperature and fuel presence, even at low torque output conditions, thereby preventing hydrocarbon build-up and extending filter longevity.
Implementation Method 1
the DOC may promote particulate filter regeneration by oxidizing soot of the particulate filter using heat from the exhaust gas flow
Implementation Method 2
oxidizing soot of the particulate filter using heat from the exhaust gas flow
Implementation Method 3
adequate combustion to prevent hydrocarbon build-up in the aftertreatment module
Data Source
AI summary
A system includes an engine adapted to output a torque, a parasitic load adapted to receive a portion of the torque from the engine, and a controller communicably coupled to the parasitic load. The controller is configured to determine an actual exhaust temperature value of an exhaust gas flow exiting the engine and a minimum fuel amount to be injected into the engine. The controller is configured to compare the actual exhaust temperature value with an exhaust temperature threshold value of the exhaust gas flow to determine a first difference between the actual exhaust temperature value and the exhaust temperature threshold value. The controller is configured to determine a target torque output of the engine based on the first difference and the minimum fuel amount. The controller is configured to cause the torque to be increased to attain the target torque output using the parasitic load.