Exhaust Purification Device with Segmented Catalyst and Muffler
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Solution Overview
Problem
In industrial vehicles like forklifts, the space constraint makes it difficult to separately dispose a downstream side purification device with a DPF and an oxidation catalyst, and when integrated with a noise reduction device (muffler), it hinders miniaturization.
Innovation Solution
An exhaust gas purification device is designed with a pre-oxidation catalyst positioned next to the engine, surrounded by a muffler that reduces noise, and a downstream purification device accommodating a larger oxidation catalyst and DPF, allowing for efficient space utilization and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the downstream side purification device and noise reduction device are disposed separately, then the purification function is ensured, but the arrangement space cannot be ensured on the rear side of the engine
Solution Approach 1:
The exhaust gas purification system is divided into two independent parts: a pre-oxidation catalyst disposed right next to the engine, and a downstream side purification device disposed downstream of the muffler. This segmentation allows the pre-oxidation catalyst to perform initial purification near the engine, while the downstream device handles final purification, enabling flexible spatial arrangement that ensures both purification function and adequate arrangement space.
Solution Approach 2:
The pre-oxidation catalyst is positioned in a different spatial location (right next to the engine) rather than following the traditional linear arrangement downstream of the muffler. This dimensional repositioning allows the system to utilize available space more effectively, ensuring both purification performance and compact arrangement on the rear side of the engine.
2Area of stationary object
If the downstream side purification device and noise reduction device are disposed integrally, then the arrangement space is reduced, but the miniaturization of the forklift becomes difficult
Solution Approach 1:
The system separates the noise reduction function (muffler) from the purification function (downstream side purification device), with the pre-oxidation catalyst serving as an independent component near the engine. This segmentation allows each component to be optimized independently, enabling the downstream purification device to be compact while maintaining full purification functionality, thus facilitating forklift miniaturization.
Solution Approach 2:
The pre-oxidation catalyst acts as an intermediary component that performs initial oxidation of exhaust gases before they reach the muffler and downstream purification device. This intermediary function reduces the burden on the downstream purification device, allowing it to be smaller in size while still achieving effective exhaust gas purification, thereby supporting forklift miniaturization.
3Reliability
If a relatively small pre-oxidation catalyst is disposed in the exhaust pipe, then the initial oxidation function is improved, but the space for downstream purification device becomes limited
Solution Approach 1:
The oxidation function is segmented into two stages: a small pre-oxidation catalyst near the engine for initial oxidation, and the downstream side purification device for final purification. This segmentation allows the pre-oxidation catalyst to be compact while performing its specific function, and the downstream device to be positioned in available space downstream of the muffler, optimizing both oxidation performance and space utilization.
Solution Approach 2:
The pre-oxidation catalyst performs preliminary oxidation of exhaust gases before they reach the muffler and downstream purification device. This preliminary action converts some exhaust components earlier in the process, reducing the workload and required size of the downstream purification device, thereby optimizing the space available for its installation.
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 configuration ensures easy arrangement of the downstream purification device and muffler, facilitating the miniaturization of the vehicle by eliminating the need for direct connection between the muffler and downstream purification device, thus enhancing noise reduction and space efficiency.
Implementation Method 1
a pre-oxidation catalyst disposed in an exhaust gas passage disposed right next to an engine mounted in a vehicle body
Implementation Method 2
a muffler that is provided in such a manner as to surround the pre-oxidation catalyst, and discharges exhaust gas generated in the engine while reducing noise
Implementation Method 3
a downstream side purification device that is disposed in the exhaust gas passage on a downstream side of the muffler, and accommodates a second oxidation catalyst that is larger than the pre-oxidation catalyst
Implementation Method 4
a downstream side purification device that is disposed in the exhaust gas passage on a downstream side of the muffler, and accommodates a second oxidation catalyst that is larger than the pre-oxidation catalyst and a particulate matter removing filter
Data Source
AI summary
An exhaust gas purification device includes a pre-oxidation catalyst disposed in an exhaust gas passage and a muffler that is provided in such a manner as to surround the pre-oxidation catalyst, and discharges exhaust gas while reducing noise. The muffler has an inlet which is connected to an upstream side exhaust pipe and an outlet which is connected to a downstream side exhaust pipe. The exhaust gas purification device includes a downstream side purification device that is disposed in the exhaust gas passage, and accommodates a second oxidation catalyst and a particulate matter removing filter. The exhaust gas is discharged to the atmosphere after the exhaust gas flows through the downstream side purification device.