Exhaust System Modeling for Sensor Reduction
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Solution Overview
Problem
The increasing number of sensors in exhaust systems for internal combustion engines leads to higher production costs due to the sensors themselves, associated wiring, and calibration requirements for different vehicle models, making it economically challenging to manage and calibrate various exhaust systems effectively.
Innovation Solution
An exhaust control system comprising an exhaust system modeling module and an actuator control module that estimates input and output gas temperatures, mass temperatures, and pressures for exhaust system components, allowing for selective adjustment of engine operating parameters to achieve desired exhaust conditions without the need for a multitude of sensors, using a generic configuration that can be adapted to different vehicle models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of sensors in the exhaust system is increased to improve measurement precision and control accuracy, then the reliability of exhaust system management is improved, but the production cost and device complexity increase
Solution Approach 1:
The patent creates a virtual copy of the exhaust system through mathematical modeling. Instead of using multiple physical sensors to directly measure exhaust parameters, the system uses a calibrated model that replicates exhaust system behavior based on limited sensor inputs (intake air mass, coolant temperature, engine speed, manifold pressure). This virtual model provides the same information as multiple physical sensors would, thereby reducing hardware complexity while maintaining measurement reliability.
Solution Approach 2:
The patent introduces a mathematical model as an intermediary between the engine control system and exhaust parameters. Rather than directly sensing exhaust temperature, pressure, and flow with multiple sensors, the system uses the calibrated model as a mediator that computes these parameters from readily available engine operating data. This intermediary approach eliminates the need for complex sensor arrays while providing reliable exhaust system management information.
2Reliability
If multiple sensors are implemented in each different vehicle and exhaust system to improve measurement accuracy, then the reliability is improved, but the ease of manufacture decreases due to calibration requirements
Solution Approach 1:
The patent develops a universal calibrated model that can be applied across multiple vehicle models and exhaust system configurations. The model uses a standardized set of inputs (intake air mass, coolant temperature, engine speed, manifold pressure) that are common to all vehicles, eliminating the need for vehicle-specific sensor calibration. This universal approach maintains measurement reliability while dramatically simplifying the manufacturing and calibration process, as the same model framework can be deployed across different vehicle platforms with minimal adjustment.
3Measurement precision
If the number of sensors and associated wiring is increased to improve exhaust system monitoring, then the measurement precision is improved, but the production cost increases
Solution Approach 1:
The patent creates a virtual representation of exhaust parameters through mathematical modeling rather than using multiple physical sensors. The calibrated model computes exhaust temperature, pressure, and flow rate with precision comparable to direct sensing, but without requiring the corresponding sensor hardware. This virtual copying approach maintains measurement precision while eliminating the need for expensive sensor arrays and associated wiring infrastructure.
Data Source
AI summary
An exhaust control system for a vehicle comprises an exhaust system modeling module and an actuator control module. The exhaust system modeling module estimates an input gas temperature, an output gas temperature, a mass temperature, and a pressure for an exhaust system component of an exhaust system implemented in the vehicle. Exhaust gas flows through the exhaust system component. The actuator control module selectively adjusts an engine operating parameter based on at least one of the input gas temperature, the output gas temperature, the mass temperature, and the pressure.