Exhaust System Active Regeneration Control
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Solution Overview
Problem
Existing exhaust systems for engines, such as diesel engines, face inefficiencies in particulate matter regeneration due to insufficient consideration of operating conditions and the insufficiency of electric heaters in oxidizing trapped soot, especially when particulate filters become saturated.
Innovation Solution
An exhaust system with a controller that determines the need to heat aftertreatment components by adjusting engine load and applying electrical power to a resistive grid within the exhaust duct, combining mechanical load increase and electrical heating to achieve the required temperature for efficient regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only electric heaters are used to raise exhaust temperature for regeneration, then the system structure is simple, but the heaters are insufficient to adequately oxidize trapped particulate matter
Solution Approach 1:
The patent combines two heating methods: electric heaters and engine load increase. The controller monitors particulate matter accumulation and selectively applies either electric heating, engine load increase, or both simultaneously to achieve the required temperature for effective oxidation, thereby resolving the insufficiency of electric heaters alone while managing system complexity.
Solution Approach 2:
The system utilizes the engine's own operation to generate heat for regeneration by increasing engine load, which naturally raises exhaust temperature. This self-service approach reduces reliance on external electric heating power and leverages the engine's operational characteristics to achieve regeneration.
2Productivity
If electric power is continuously applied to raise exhaust temperature, then regeneration efficiency improves, but energy consumption increases
Solution Approach 1:
The controller implements periodic regeneration cycles by monitoring particulate matter accumulation in the filter. Electric heating and engine load increase are applied only when regeneration is needed, rather than continuously, thereby maintaining high regeneration efficiency while minimizing energy consumption during normal operation.
Solution Approach 2:
The system dynamically adjusts exhaust temperature parameters by varying engine load and electric heater power based on real-time monitoring of filter saturation levels. This allows the system to achieve necessary temperature elevation only when required, optimizing the balance between regeneration efficiency and energy consumption.
3Temperature
If engine load is increased to raise exhaust temperature, then heating effectiveness improves, but engine performance and fuel consumption are affected
Solution Approach 1:
The controller applies engine load increase as a partial heating solution, combining it with electric heaters when needed. By using a combination of both methods, the system achieves the required exhaust temperature with minimal engine load increase, thereby reducing the impact on fuel consumption while maintaining effective heating.
Solution Approach 2:
The electric heater acts as an intermediary that supplements engine load increase. When engine load increase alone is insufficient or would cause excessive fuel consumption, the electric heater provides additional heating to achieve the target temperature, thereby reducing the need for excessive engine load increases and associated 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 allows for more efficient and controlled temperature elevation of exhaust gases, ensuring optimal operation of aftertreatment components like particulate filters, even when electric heaters alone are insufficient, thereby improving regeneration efficiency and extending filter lifespan.
Implementation Method 1
a resistive grid disposed within the exhaust duct at a location upstream of the aftertreatment component
Implementation Method 2
soot trapped in an exhaust particulate trap is oxidized
Implementation Method 3
heated above a combustion threshold of the trapped particulate matter such that the particulate matter is burned away
Data Source
AI summary
An exhaust system is disclosed for use with an engine. The exhaust system may have an exhaust duct, an aftertreatment component disposed within the exhaust duct, and a resistive grid disposed within the exhaust duct at a location upstream of the aftertreatment component. The exhaust system may further have a controller configured to determine a need to heat the aftertreatment component to a threshold temperature, determine a load increase that should be placed on the engine to raise a temperature of exhaust exiting the engine when the aftertreatment component needs to be heated, and determine an amount of electrical power that should be applied to the resistive grid to raise the temperature of the exhaust. The controller may also be configured to selectively implement a combination of engine load increase and application of electrical power to the resistive grid to raise the temperature of exhaust to the threshold temperature.