Fuel Post Injection Timing for DPF Regeneration

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Solution Overview

Problem

Existing diesel particulate filter (DPF) regeneration methods face challenges during cylinder deactivation and engine braking, where fuel post injection timing is not precisely controlled, leading to wall wetting and fuel-in-oil dilution, and inefficient regeneration due to exhaust cooling.

Innovation Solution

Injecting fuel within a threshold crank angle range around top dead center of both compression and exhaust strokes, adjusting air flow, and determining optimal fuel injection timings to enhance mixing and reduce the likelihood of ignition, while fully closing the EGR valve and adjusting the VGT to prevent recirculation and optimize exhaust backpressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If fuel post injection is performed during cylinder deactivation or engine braking to generate exotherms for DPF regeneration, then exhaust temperature increases and regeneration is enabled, but wall wetting and fuel-in-oil dilution occur due to imprecise injection timing

Engineering Contradiction:
Improveexhaust temperatureVSAvoidwall wetting and fuel-in-oil dilution
Core Design Contradiction:
TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes by precisely controlling the fuel post injection timing within a specific crank angle range (within 40 degrees before and after top dead center). This timing parameter optimization ensures that fuel is injected when the piston is near the top of its stroke, allowing the fuel to be drawn into the exhaust system through the exhaust valve rather than remaining in the cylinder where it would cause wall wetting and oil dilution. The exact timing parameter control resolves the contradiction between generating sufficient exhaust temperature for regeneration and avoiding harmful fuel deposition in the cylinder.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent implements dynamics by adapting the fuel post injection strategy specifically for cylinder deactivation and engine braking conditions. The system dynamically adjusts injection timing based on the operational state, ensuring that during these specific conditions where combustion is discontinued, the injection timing precisely targets the exhaust system entry point. This dynamic adaptation allows exotherm generation while preventing the fuel from settling on cylinder walls or mixing with oil.

Inventive Principle:
Principle #15Dynamics

2Use of energy by moving object

If fuel post injection timing is extended beyond the threshold crank angle range to ensure complete fuel combustion, then energy utilization improves, but the likelihood of wall wetting and fuel-in-oil dilution increases

Engineering Contradiction:
Improvefuel combustion efficiencyVSAvoidwall wetting and fuel-in-oil dilution
Core Design Contradiction:
Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies the extraction principle by removing the fuel from the cylinder environment at the critical moment when the piston approaches top dead center. By timing the injection to coincide with the piston at or near TDC and leveraging the exhaust valve opening, the fuel is extracted from the cylinder space and directed into the exhaust system. This extraction prevents the fuel from remaining in the cylinder where it would otherwise continue to combust incompletely or deposit on walls, thereby resolving the contradiction between complete combustion and avoiding wall wetting.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The exhaust system acts as an intermediary medium that receives the post-injected fuel. By timing the injection to occur when the exhaust valve is open or about to open, the fuel uses the exhaust gas flow as a carrier to transport it out of the cylinder and into the exhaust system where combustion can complete in the DPF or downstream catalyst. This intermediary mechanism allows the fuel to combust completely without contacting cylinder walls or mixing with oil.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Loss of energy

If combustion is discontinued in one or more cylinders during engine braking or cylinder deactivation, then fuel economy improves, but exhaust temperature decreases and DPF regeneration becomes inefficient

Engineering Contradiction:
Improvefuel economyVSAvoidexhaust temperature
Core Design Contradiction:
Loss of energyVSTemperature

Solution Approach 1:

The patent applies preliminary action by injecting the fuel just before or at the moment the exhaust valve opens, during the brief period when the piston is at top dead center. This timing ensures that the fuel is introduced into the cylinder at the optimal moment to be swept into the exhaust system, generating exotherms that raise exhaust temperature for DPF regeneration. This preliminary, precisely-timed injection enables temperature maintenance during fuel economy modes without requiring continuous combustion in all cylinders.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements periodic action through the cyclic nature of the fuel post injection, which occurs once per engine cycle in the specific crank angle window. This periodic injection, synchronized with the engine's natural cycle and exhaust valve timing, creates regular exothermic events that maintain exhaust temperature throughout the regeneration process while allowing cylinders to remain in fuel economy mode between injection events.

Inventive Principle:
Principle #19Periodic action

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 generates exotherms for DPF regeneration with reduced wall wetting and fuel-in-oil dilution, maintaining exhaust temperatures and improving regeneration efficiency even during cylinder deactivation and engine braking.

Implementation Method 1

injecting fuel into a cylinder within a threshold crank angle range around top dead center of a compression stroke of the cylinder and also within the threshold crank angle range around top dead center of an exhaust stroke of the cylinder

Methodology Applied
Scientific EffectCombustion: Combustion

Implementation Method 2

generating exotherms in an exhaust system of an engine

Methodology Applied
Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 3

fully closing the EGR valve

Methodology Applied
Scientific EffectValve closure: Valve

Implementation Method 4

adjusting the VGT to prevent recirculation and optimize exhaust backpressure

Methodology Applied
Scientific EffectTurbine flow control: Turbine

Data Source

PatentUS20220282678A1Systems and methods for fuel post injection timing
Publication Date: 2022.09.08 FORD GLOBAL TECH LLC
  • US20220282678A1 patent drawing
  • US20220282678A1 patent drawing
  • US20220282678A1 patent drawing

AI summary

Methods and systems are provided for fuel post injection for diesel particulate filter (DPF) regeneration. In one example, a method may include, responsive to a request for generating exotherms in an exhaust system of an engine while combustion is discontinued in at least one cylinder of the engine, injecting fuel into a cylinder within a threshold crank angle range around top dead center (TDC) of a compression stroke of the cylinder and also within the threshold crank angle range around top dead center of an exhaust stroke of the cylinder, the threshold crank angle range extending from no more than 40 crank angle degrees before TDC to no more than 40 crank angle degrees after TDC. In this way, fuel post injections may be injected +/−40 crank angle degrees after TDC of the compression and exhaust strokes to increase exhaust temperature while avoiding wall wetting and oil-in-fuel dilution.