Exhaust Stack Cooling via Mixing with Blower Fan Air
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Solution Overview
Problem
Skid steer machines face challenges in managing high temperatures during diesel particulate filter regeneration, particularly in compact designs where exhaust gas temperatures exceed 300 degrees Celsius, posing risks to operators and bystanders due to inadequate cooling strategies.
Innovation Solution
A system that mixes exhaust gas with cooling air from a blower fan in a high temperature zone surrounding the exhaust stack outlet, utilizing an electronic control module to regulate the blower fan speed and ensure the exhaust gas is cooled to below 200 degrees Celsius, thereby reducing the temperature in the vicinity of the diesel particulate filter during regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If exhaust gas is directly discharged from the exhaust stack outlet, then the regeneration process is maintained, but high temperatures exceed 300 degrees Celsius posing risks to operators and bystanders
Solution Approach 1:
Cooling air is introduced as an intermediary substance between the hot exhaust gas and the surrounding environment. The cooling air mixes with the exhaust gas in the high temperature zone, acting as a mediator to reduce the temperature of the discharged gases while allowing the regeneration process to continue effectively
2Temperature
If cooling air is mixed with exhaust gas to reduce temperature, then operator safety is improved, but the temperature of the fluid mixture must be maintained within the high temperature zone
Solution Approach 1:
A feedback control system monitors the temperature of the fluid mixture and adjusts the blower fan speed accordingly. The electronic control module receives temperature data and modifies the cooling air flow rate to maintain the temperature within the desired high temperature zone, ensuring both safety and regeneration effectiveness
Solution Approach 2:
The blower fan speed is made dynamic rather than fixed. The system continuously adjusts the fan speed based on real-time temperature conditions, allowing the cooling rate to adapt to varying exhaust gas temperatures and flow conditions while maintaining precise temperature control in the high temperature zone
3Object-affected harmful factors
If a blower fan is used to supply cooling air, then cooling effectiveness is improved, but the system complexity and energy consumption increase
Solution Approach 1:
The blower fan serves multiple functions: it supplies cooling air to the exhaust stack, draws air through the heat exchanger, and its speed can be adjusted to control the mixing ratio. This multi-functionality reduces the need for separate components and simplifies the overall system architecture while maintaining effective temperature control
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 effectively cools the exhaust gas to temperatures below 150 degrees Celsius at the perimeter of the high temperature zone, reducing the risk of heat exposure for operators and bystanders while maintaining efficient regeneration of the diesel particulate filter.
Implementation Method 1
The blower fan is configured to blow cooling air from the engine compartment sequentially through the at least one heat exchanger and an outlet of the cooling package
Implementation Method 2
A cooling package including at least one heat exchanger and a blower fan
Implementation Method 3
Exhaust gas exiting the exhaust stack outlet is mixed with the cooling air exiting the cooling package outlet in a high temperature zone surrounding the exhaust stack outlet to form a fluid mixture
Data Source
AI summary
A machine includes an internal combustion engine disposed within an engine compartment and supported on a machine frame. An exhaust stack has an inlet fluidly connected to an exhaust manifold of the internal combustion engine and an outlet in fluid communication with ambient air. A diesel particulate filter is disposed along the exhaust stack, and the machine includes an active regeneration system for regenerating the diesel particulate filter. A cooling package including at least one heat exchanger and a blower fan. The blower fan is configured to blow cooling air from the engine compartment sequentially through the at least one heat exchanger and an outlet of the cooling package. Exhaust gas exiting the exhaust stack outlet is mixed with the cooling air exiting the cooling package outlet in a high temperature zone surrounding the exhaust stack outlet to form a fluid mixture. An electronic control module is in control communication with the active regeneration system and includes a regeneration control algorithm operable to detect a speed of the blower fan.