DPF Regeneration Control for Forklift Exhaust Temperature
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Solution Overview
Problem
Engine-powered forklifts with low-speed, low-load operations face challenges in natural DPF regeneration due to inadequate exhaust gas temperature, leading to periodic interruptions and safety risks, particularly in torque converter driven types where conventional DPF regeneration systems are not applicable.
Innovation Solution
A system that controls the load of an electro-hydraulic pump and engine speed to regenerate the DPF during operation, eliminating the need for periodic forced regeneration, by monitoring the forklift's state and adjusting the hydraulic load or engine speed to maintain optimal regeneration conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the forklift operates at low speed with low load, then the exhaust gas temperature remains insufficient for natural DPF regeneration, but increasing engine speed or load to enable regeneration may cause engine overload and sudden shutdown
Solution Approach 1:
The patent introduces a DPF regeneration device as an intermediary component that can be selectively activated. This device includes a fuel injection system that injects fuel into the exhaust stream downstream of the DPF, creating a controlled combustion zone that raises exhaust temperature without requiring the engine to operate at high load conditions. The regeneration device acts as a mediator between the low-power engine operation and the high-temperature regeneration requirement.
Solution Approach 2:
The system changes the operational parameters by controlling the injection timing and amount of fuel into the exhaust stream. By injecting fuel downstream of the DPF at specific engine operating conditions (when engine speed is below a predetermined threshold and DPF differential pressure indicates regeneration need), the system creates localized high-temperature zones that enable regeneration without increasing overall engine load or speed.
2Adaptability or versatility
If conventional DPF regeneration systems are applied to torque converter driven forklifts, then the system cannot be properly adapted to the traveling mode, but modifying the system increases device complexity
Solution Approach 1:
The patent designs a universal DPF regeneration system that can be applied to both hydraulic pump driven and torque converter driven forklifts. The control unit monitors engine operating parameters and DPF differential pressure across different traveling modes and automatically activates the regeneration device when conditions are appropriate. This multi-functional approach allows the same system architecture to serve different forklift propulsion types without requiring mode-specific modifications.
3Reliability
If periodic forced regeneration is performed, then the DPF can be regenerated, but the forklift operation must be interrupted which reduces work performance
Solution Approach 1:
The patent enables continuous DPF regeneration during forklift operation by activating the regeneration device while the engine continues to operate. The fuel injection into the exhaust stream occurs concurrently with normal forklift operation, allowing regeneration to proceed without interrupting the useful work. The control unit manages the regeneration process in a way that maintains continuous operation rather than requiring periodic shutdowns.
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
Enables continuous DPF regeneration without forced interruptions, improving work performance and ensuring safety in engine-powered forklifts, including torque converter driven types, by maintaining optimal regeneration conditions and preventing engine overload.
Implementation Method 1
a diesel particulate filter (hereinafter, 'DPF') for collecting particulate matter from exhaust gas discharged from an engine to an exhaust path
Implementation Method 2
it is necessary to increase the temperature of the exhaust gas through the post-fuel injection
Data Source
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AI summary
The present disclosure is related to a system for regenerating a DPF and a method thereof. The system for regenerating a DPF during operation of an engine-powered forklift that includes the DPF for collecting particulate matter form exhaust gas discharged from an engine to an exhaust path includes: an engine control unit for controlling operation of the engine; an electro-hydraulic pump for discharging a working fluid that generates a hydraulic load; a control unit for determining a state of the forklift when a DPF regeneration request signal is received from the engine control unit, and controlling at least one of the hydraulic load of the electro-hydraulic pump and revolutions per minute of the engine according to the determined state of the forklift; and a diesel oxidation catalyst unit for regenerating the DPF according to the control of the control unit. According to one or more embodiments of the present invention, it is possible to regenerate a DPF in an engine-powered forklift without periodic forced regeneration of the DPF during operation of the engine-powered forklift, by controlling at least one of a load of an electro-hydraulic pump and an engine speed of an engine. Accordingly, the performance of works may be improved, and the safety may be ensured in the engine-powered forklift.